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PowerXL DG1 Series VFD
Installation Manual
Effective March 2014
New Information
PowerXL DG1 Series VFD
Disclaimer of Warranties and Limitation of Liability
The information, recommendations, descriptions, and safety notations in this document are
based on Eaton’s experience and judgment and may not cover all contingencies. If further
information is required, an Eaton sales office should be consulted. Sale of the product shown
in this literature is subject to the terms and conditions outlined in appropriate Eaton selling
policies or other contractual agreement between Eaton and the purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR
MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING
CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE
OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME
PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including
negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever, including but not limited to damage or loss of use of equipment,
plant or power system, cost of capital, loss of power, additional expenses in the use of
existing power facilities, or claims against the purchaser or user by its customers resulting
from the use of the information, recommendations, and descriptions contained herein. The
information contained in this manual is subject to change without notice.
Cover Photo: Eaton PowerXL DG1 Series Drive
PowerXL DG1 Series VFD
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PowerXL DG1 Series VFD
Support Services
Support Services
The goal of Eaton is to ensure your greatest possible satisfaction with the operation of our
products. We are dedicated to providing fast, friendly, and accurate assistance. That is why
we offer you so many ways to get the support you need. Whether it is by phone, fax, or
email, you can access Eaton’s support information 24 hours a day, seven days a week.
Our wide range of services is listed below.
You should contact your local distributor for product pricing, availability, ordering, expediting,
and repairs.
Website
Use the Eaton Website to find product information. You can also find information on local
distributors or Eaton’s sales offices.
Website Address
www.eaton.com/drives
EatonCare Customer Support Center
Call the EatonCare Support Center if you need assistance with placing an order, stock
availability or proof of shipment, expediting an existing order, emergency shipments, product
price information, returns other than warranty returns, and information on local distributors or
sales offices.
Voice: 877-ETN-CARE (386-2273) (8:00 a.m.–6:00 p.m. EST)
After-Hours Emergency: 800-543-7038 (6:00 p.m.–8:00 a.m. EST)
Drives Technical Resource Center
Voice: 877-ETN-CARE (386-2273) option 2, option 6
(8:00 a.m.–5:00 p.m. Central Time U.S. [UTC –6])
email: [email protected]
For Customers in Europe, Contact
Phone: +49 (0) 228 6 02-3640
Hotline: +49 (0) 180 5 223822
email: [email protected]
www.eaton.com/moeller/aftersales
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PowerXL DG1 Series VFD
Table of Contents
SAFETY
Before Commencing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazardous High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and Equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHAPTER 1—DG1 SERIES OVERVIEW
How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Real Time Clock Battery Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carton Labels (U.S. and Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catalog Number System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Ratings and Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1
2
2
3
4
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CHAPTER 2—ENGINEERING CONSIDERATIONS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Power Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Voltage and Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Voltage Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Total Harmonic Distortion (THD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reactive Power Compensation Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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10
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11
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CHAPTER 3—PRODUCT OVERVIEW
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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14
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CHAPTER 4—SAFETY AND SWITCHING
Fuses and Cable Cross-Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cables and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Residual-Current Device (RCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHAPTER 5—MOTOR AND APPLICATION
Motor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Motors in Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Connection of Several Motors to One Frequency Inverter . . . . . . . . . .
Motor and Circuit Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting EX Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents, continued
CHAPTER 6—INSTALLATION REQUIREMENTS
Electrical Installation Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Drive Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wiring Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Selection: Power and Motor Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line (Mains) and Motor Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rubber Grommet Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Torque Off (STO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection to Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three-Phase Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Designations in the Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Modified Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Cable and Motor Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHAPTER 7—EMC INSTALLATION
EMC Measures in the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screen Earth Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
International EMC Protection Cable Requirements . . . . . . . . . . . . . . . . . . . . . .
Installation in Corner-Grounded Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation in IT System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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APPENDIX A—TECHNICAL DATA AND SPECIFICATIONS
APPENDIX B—INSTALLATION GUIDELINES
Cable and Fuse Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Deratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Loss Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Resistor Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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50
54
54
APPENDIX C—DIMENSION DRAWINGS
APPENDIX D—SAFETY INSTRUCTIONS FOR UL AND CUL
UL Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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List of Figures
Figure 1. RTC Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2. Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3. Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4. Drive System (PDS = Power Drive System) . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5. AC Power Networks with Grounded Neutral Point (TN- / TT Networks) . . . . .
Figure 6. Description of the DG1 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7. Block Diagram, Elements of DG1 Frequency Inverters . . . . . . . . . . . . . . . . . .
Figure 8. Selection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9. Identification on the FI Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10. EMC Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11. Parallel Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12. Example of a Motor Ratings Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13. Star and Delta Circuit Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14. V/Hz Characteristic Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 15. Bypass Motor Control (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16. Mounting Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17. Type 1/12 Open Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 18. Input Power and Motor Cable Stripping Lengths . . . . . . . . . . . . . . . . . . . . .
Figure 19. Ground Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 20. Terminal Block Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 21. Basic Internal Control Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 22. DG1 Series Adjustable Frequency Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 23. Thermistor STO Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 24. Connection to Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 25. Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 26. Product Modified Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 27. EMC-Compliant Setup—460/480 Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 28. Cable Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 29. Locations of the EMC Screw in
Frame 1, Frame 2, Frame 3 and Frame 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 30. Locations of the EMC Screws in Frame 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 31. FR1 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 32. FR1 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 33. FR2 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 34. FR2 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 35. FR3 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 36. FR3 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 37. FR4 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 38. FR4 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 39. FR5 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 40. FR5 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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PowerXL DG1 Series VFD
List of Tables
Table 1. Common Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2. Type 1/IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3. Type 12/IP54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4. Type 1/IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 5. Type 12/IP54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6. Frame 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7. Frame 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8. Frame 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9. Frame 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 10. Frame 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 11. Drive System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 12. Elements of DG1 Frequency Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 13. Maintenance Measures and Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 14. Maximum Motor Cable Length by Frame Size
without dV/dT Protected C2 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 15. Assignment of Frequency Inverters to Example Motor Circuit . . . . . . . . . . . .
Table 16. Bypass Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 17. Space Requirements for Mounting the DG1 Series VFD and Airflow . . . . . . .
Table 18. Mounting Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 19. Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 20. Spacing Between Parallel Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 21. Maximum Motor Cable Length by Frame Size
without dV/dT Protected C2 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 22. Input Power and Motor Cable Stripping and Wire Lengths . . . . . . . . . . . . . .
Table 23. I/O Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 24. I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 25. 1st Environment 2nd Environment EMC Levels
According to EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 26. Control Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 27. Cable Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 28. PowerXL Series—DG1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 29. North America Cable and Fuse Sizes—208 Vac to 240 Vac Ratings . . . . . . . .
Table 30. International Cable and Fuse Sizes—208 Vac to 240 Vac Ratings . . . . . . . . .
Table 31. North America Cable and Fuse Sizes—440 Vac to 500 Vac Ratings . . . . . . . .
Table 32. International Cable and Fuse Sizes—380 Vac to 440 Vac Ratings . . . . . . . . .
Table 33. 230V Temperature and Switching Frequency Deratings (VT) . . . . . . . . . . . . .
Table 34. 230V Temperature and Switching Frequency Deratings (CT) . . . . . . . . . . . . .
Table 35. 460V Temperature and Switching Frequency Deratings (VT) . . . . . . . . . . . . .
Table 36. 460V Temperature and Switching Frequency Deratings (CT) . . . . . . . . . . . . .
Table 37. Heat Loss Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 38. Brake Resistor Sizing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 39. Fuse Ratings—400V Drive Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 40. Fuse Ratings—230V Drive Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 41. Required Line and Motor Wire Torque (400V) . . . . . . . . . . . . . . . . . . . . . . . . .
Table 42. Required Line and Motor Wire Torque (230V) . . . . . . . . . . . . . . . . . . . . . . . .
Table 43. Required Line and Motor Wire Torque (400V) . . . . . . . . . . . . . . . . . . . . . . . .
Table 44. Required Line and Motor Wire Torque (230V) . . . . . . . . . . . . . . . . . . . . . . . .
vi
PowerXL DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
1
4
4
5
5
6
6
7
7
8
9
13
15
18
21
22
24
25
29
29
29
30
34
35
42
42
42
44
46
47
48
49
50
51
52
53
54
54
65
66
66
67
67
68
PowerXL DG1 Series VFD
Safety
Warning!
Dangerous Electrical Voltage!
Before Commencing the Installation
●
Disconnect the power supply of the device
●
Ensure that devices cannot be accidentally restarted
●
Verify isolation from the supply
●
Earth and short circuit the device
●
Cover or enclose any adjacent live components
●
Only suitably qualified personnel in accordance with
EN 50110-1/-2 (VDE 0105 Part 100) may work on this
device/system
●
Before installation and before touching the device ensure
that you are free of electrostatic charge
●
The functional earth (FE, PES) must be connected to the
protective earth (PE) or the potential equalization. The
system installer is responsible for implementing this
connection
●
Connecting cables and signal lines should be installed so
that inductive or capacitive interference does not impair
the automation functions
●
Install automation devices and related operating elements
in such a way that they are well protected against
unintentional operation
●
Suitable safety hardware and software measures should
be implemented for the I/O interface so that an open
circuit on the signal side does not result in undefined
states in the automation devices
●
Ensure a reliable electrical isolation of the extra-low
voltage of the 24V supply. Only use power supply units
complying with IEC 60364-4-41 (VDE 0100 Part 410) or
HD384.4.41 S2
●
Deviations of the input voltage from the rated value must
not exceed the tolerance limits given in the specifications,
otherwise this may cause malfunction and dangerous
operation
●
Emergency stop devices complying with IEC/EN 60204-1
must be effective in all operating modes of the automation
devices. Unlatching the emergency-stop devices must not
cause a restart
●
Devices that are designed for mounting in housings or
control cabinets must only be operated and controlled after
they have been installed and with the housing closed.
Desktop or portable units must only be operated and
controlled in enclosed housings
●
Measures should be taken to ensure the proper restart of
programs interrupted after a voltage dip or failure. This
should not cause dangerous operating states even for a
short time. If necessary, emergency-stop devices should
be implemented
●
Wherever faults in the automation system may cause
injury or material damage, external measures must be
implemented to ensure a safe operating state in the event
of a fault or malfunction (for example, by means of
separate limit switches, mechanical interlocks, and so on)
●
Depending on their degree of protection, adjustable
frequency drives may contain live bright metal parts,
moving or rotating components, or hot surfaces during and
immediately after operation
●
Removal of the required covers, improper installation, or
incorrect operation of motor or adjustable frequency drive
may cause the failure of the device and may lead to
serious injury or damage
●
The applicable national accident prevention and safety
regulations apply to all work carried out on live adjustable
frequency drives
●
The electrical installation must be carried out in
accordance with the relevant regulations (for example,
with regard to cable cross sections, fuses, PE)
●
Transport, installation, commissioning, and maintenance
work must be carried out only by qualified personnel
(IEC 60364, HD 384 and national occupational safety
regulations)
●
Installations containing adjustable frequency drives must
be provided with additional monitoring and protective
devices in accordance with the applicable safety
regulations. Modifications to the adjustable frequency
drives using the operating software are permitted
●
All covers and doors must be kept closed during operation
●
To reduce hazards for people or equipment, the user must
include in the machine design measures that restrict the
consequences of a malfunction or failure of the drive
(increased motor speed or sudden standstill of motor).
These measures include:
●
Other independent devices for monitoring safety-related
variables (speed, travel, end positions, and so on)
●
Electrical or non-electrical system-wide measures
(electrical or mechanical interlocks)
●
Never touch live parts or cable connections of the
adjustable frequency drive after it has been
disconnected from the power supply. Due to the charge
in the capacitors, these parts may still be live after
disconnection. Fit appropriate warning signs
PowerXL DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
vii
PowerXL DG1 Series VFD
Read this manual thoroughly and make sure you understand
the procedures before you attempt to install, set up, operate
or carry out any maintenance work on this DG1 Adjustable
Frequency Drive.
Definitions and Symbols
WARNING
WARNING
The components in the drive’s power section remain
energized after the supply voltage has been switched off.
After disconnecting the supply, wait at least five minutes
before removing the cover to allow the intermediate
circuit capacitors to discharge.
Pay attention to hazard warnings!
This symbol indicates high voltage. It calls your attention
to items or operations that could be dangerous to you
and other persons operating this equipment. Read the
message and follow the instructions carefully.
DANGER
This symbol is the “Safety Alert Symbol.” It occurs with
either of two signal words: CAUTION or WARNING, as
described below.
WARNING
5 MIN
WARNING
Electric shock hazard—risk of injuries! Carry out wiring
work only if the unit is de-energized.
Indicates a potentially hazardous situation which, if not
avoided, can result in serious injury or death.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, can result in minor to moderate injury, or serious
damage to the product. The situation described in the
CAUTION may, if not avoided, lead to serious results.
Important safety measures are described in CAUTION (as
well as WARNING).
Hazardous High Voltage
WARNING
Motor control equipment and electronic controllers are
connected to hazardous line voltages. When servicing
drives and electronic controllers, there may be exposed
components with housings or protrusions at or above
line potential. Extreme care should be taken to protect
against shock.
●
Stand on an insulating pad and make it a habit to use
only one hand when checking components.
●
Always work with another person in case an
emergency occurs.
●
Disconnect power before checking controllers or
performing maintenance.
●
Be sure equipment is properly earthed.
●
Wear safety glasses whenever working on electronic
controllers or rotating machinery.
viii
PowerXL DG1 Series VFD
MN040002EN—March 2014
WARNING
Do not perform any modifications on the AC drive when
it is connected to mains.
Warnings and Cautions
WARNING
Be sure to ground the unit following the instructions in
this manual. Ungrounded units may cause electric shock
and/or fire.
WARNING
This equipment should only be installed, adjusted, and
serviced by qualified electrical maintenance personnel
familiar with the construction and operation of this type
of equipment and the hazards involved. Failure to
observe this precaution could result in death or severe
injury.
WARNING
Components within the drive are live when it is
connected to power. Contact with this voltage is
extremely dangerous and may cause death or severe
injury.
WARNING
Line terminals (L1, L2, L3), motor terminals (U, V, W) and
the DC link/brake resistor terminals (DC–, DC+/R+, R–)
are live when the drive is connected to power, even if the
motor is not running. Contact with this voltage is
extremely dangerous and may cause death or severe
injury.
www.eaton.com
PowerXL DG1 Series VFD
WARNING
WARNING
Even though the control I/O-terminals are isolated from
line voltage, the relay outputs and other I/O-terminals
may have dangerous voltage present even when the
drive is disconnected from power. Contact with this
voltage is extremely dangerous and may cause death or
severe injury.
WARNING
This equipment has a large capacitive leakage current
during operation, which can cause enclosure parts to be
above ground potential. Proper grounding, as described
in this manual, is required. Failure to observe this
precaution could result in death or severe injury.
WARNING
Before applying power to this drive, make sure that the
front and cable covers are closed and fastened to prevent
exposure to potential electrical fault conditions. Failure
to observe this precaution could result in death or severe
injury.
WARNING
An upstream disconnect/protective device must be
provided as required by the National Electric Code®
(NEC®). Failure to follow this precaution may result in
death or severe injury.
WARNING
This drive can cause a DC current in the protective
earthing conductor. Where a residual current-operated
protective (RCD) or monitoring (RCM) device is used for
protection in case of direct or indirect contact, only an
RCD or RCM of Type B is allowed on the supply side of
this product.
Before opening the drive covers:
●
Disconnect all power to the drive, including external
control power that may be present.
●
Wait a minimum of five minutes after all the lights on
the keypad are off. This allows time for the DC bus
capacitors to discharge.
●
A hazard voltage may still remain in the DC bus
capacitors even if the power has been turned off.
Confirm that the capacitors have fully discharged by
measuring their voltage using a multimeter set to
measure the DC voltage.
Failure to follow these precautions may cause death or
severe injury.
WARNING
The opening of the branch-circuit protective device may
be an indication that a fault current has been interrupted.
To reduce the risk of fire or electric shock, current-carrying
parts and other components of the controller should
be examined and replaced if damaged. If burnout of the
current element of an overload relay occurs, the complete
overload relay must be replaced.
WARNING
Operation of this equipment requires detailed
installation and operation instructions provided in the
Installation/Operation manual intended for use with this
product. This information is provided on the CD-ROM,
floppy diskette(s) or other storage device included in the
container this device was packaged in. it should be
retained with this device at all times. A hard copy of this
information may be ordered from Eaton literature
fulfillment.
WARNING
Carry out wiring work only after the drive has been
correctly mounted and secured.
PowerXL DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
ix
PowerXL DG1 Series VFD
WARNING
Before servicing the drive:
●
Disconnect all power to the drive, including external
control power that may be present.
●
Place a “DO NOT TURN ON” label on the disconnect
device.
●
Lock the disconnect device in the open position.
Failure to follow these instructions will result in death or
serious injury.
WARNING
The drive outputs (U, V, W) must not be connected to the
input voltage or the utility line power as severe damage
to the device may occur and there may be a risk of fire.
WARNING
The heat sink and/or outer enclosure may reach a high
temperature.
Pay attention to hazard warnings!
CAUTION
Install this drive in a well-ventilated room that is not subject
to temperature extremes, high humidity, or condensation,
and avoid locations that are directly exposed to sunlight, or
have high concentrations of dust, corrosive gas, explosive
gas, inflammable gas, grinding fluid mist, etc. Improper
installation may result in a fire hazard.
CAUTION
When selecting the cable cross-section, take the voltage
drop under load conditions into account. The consideration of
other standards is the responsibility of the user.
The user is responsible for compliance with all international
and national electrical standards in force concerning
protective grounding of all equipment.
CAUTION
The specified minimum PE conductor cross-sections in this
manual must be maintained.
Touch current in this equipment exceeds 3.5 mA (AC). The
minimum size of the protective earthing conductor shall
comply with the requirements of EN 61800-5-1 and/or the
local safety regulations.
CAUTION
Hot Surface—Risk of Burn. DO NOT TOUCH!
CAUTION
Any electrical or mechanical modification to this drive without
prior written consent of Eaton will void all warranties and may
result in a safety hazard in addition and voiding of the UL®
listing.
CAUTION
Install this drive on flame-resistant material such as a steel
plate to reduce the risk of fire.
CAUTION
Install this drive on a perpendicular surface that is able to
support the weight of the drive and is not subject to
vibration, to lessen the risk of the drive falling and being
damaged and/or causing personal injury.
CAUTION
Prevent foreign material such as wire clippings or metal
shavings from entering the drive enclosure, as this may
cause arcing damage and fire.
x
PowerXL DG1 Series VFD
MN040002EN—March 2014
Touch currents in this frequency inverter are greater than
3.5 mA (AC). According to product standard IEC/EN
61800-5-1, an additional equipment grounding conductor of
the same cross-sectional area as the original protective
earthing conductor must be connected, or the cross-section
of the equipment grounding conductor must be at least
10 mm2 Cu. Drive requires that only copper conductor should
be used.
CAUTION
Debounced inputs may not be used in the safety circuit
diagram. Residual current circuit breakers (RCD) are only to
be installed between the AC power supply network and the
drive.
CAUTION
Debounced inputs may not be used in the safety circuit
diagram. If you are connecting multiple motors on one drive,
you must design the contactors for the individual motors
according to utilization category AC-3.
Selecting the motor contactor is done according to the rated
operational current of the motor to be connected.
www.eaton.com
PowerXL DG1 Series VFD
CAUTION
CAUTION
Debounced inputs may not be used in the safety circuit
diagram. A changeover between the drive and the input
supply must take place in a voltage-free state.
CAUTION
CAUTION
Debounced inputs may not be used in the safety circuit
diagram. Fire hazard!
Only use cables, protective switches, and contactors that
feature the indicated permissible nominal current value.
CAUTION
Before connecting the drive to AC mains make sure that the
EMC protection class settings of the drive are appropriately
made according to instructions in this manual.
●
●
●
If the drive is to be used in a floating distribution network,
remove screws at MOV and EMC. See “Installation in
Corner-Grounded Network” on Page 43 and “Installation in
IT System” on Page 43 respectively.
Disconnect the internal EMC filter when installing the drive
on an IT system (an ungrounded power system or a
high-resistance-grounded [over 30 ohm] power system),
otherwise the system will be connected to ground
potential through the EMC filter capacitors. This may
cause danger, or damage the drive.
Disconnect the internal EMC filter when installing the drive
on a corner grounded TN system, otherwise the drive will
be damaged.
Note: When the internal EMC filter is disconnected, the
drive might be not EMC compatible.
●
Do not touch any components on the circuit boards. Static
voltage discharge may damage the components.
Do not attempt to install or remove the MOV or EMC
screws while power is applied to the drive’s input
terminals.
Before starting the motor, check that the motor is mounted
properly and aligned with the driven equipment. Ensure that
starting the motor will not cause personal injury or damage
equipment connected to the motor.
CAUTION
Set the maximum motor speed (frequency) in the drive
according to the requirements of the motor and the
equipment connected to it. Incorrect maximum frequency
settings can cause motor or equipment damage and personal
injury.
CAUTION
Before reversing the motor rotation direction, ensure that
this will not cause personal injury or equipment damage.
CAUTION
Make sure that no power correction capacitors are
connected to the drive output or the motor terminals to
prevent drive malfunction and potential damage.
CAUTION
Make sure that the drive output terminals (U, V, W) are not
connected to the utility line power as severe damage to the
drive may occur.
CAUTION
When the control terminals of two or more drive units are
connected in parallel, the auxiliary voltage for these control
connections must be taken from a single source which can
either be one of the units or an external supply.
Motor and Equipment Safety
CAUTION
CAUTION
Do not perform any meggar or voltage withstand tests on
any part of the drive or its components. Improper testing may
result in damage.
CAUTION
Prior to any tests or measurements of the motor or the
motor cable, disconnect the motor cable at the drive output
terminals (U, V, W) to avoid damaging the drive during motor
or cable testing.
The drive will start up automatically after an input voltage
interruption if the external run command is on.
CAUTION
Do not control the motor with the disconnecting device
(disconnecting means); instead, use the control panel start
and stop keys and, or commands via the I/O board of the
drive. The maximum allowed number of charging cycles of
the DC capacitors (i.e. power-ups by applying power) is five in
ten minutes.
PowerXL DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
xi
PowerXL DG1 Series VFD
CAUTION
Improper drive operation:
●
If the drive is not turned on for a long period, the
performance of its electrolytic capacitors will be reduced.
●
If it is stopped for a prolonged period, turn the drive on at
least every six months for at least 5 hours to restore the
performance of the capacitors, and then check its
operation. It is recommended that the drive is not
connected directly to the line voltage. The voltage should
be increased gradually using an adjustable AC source.
Failure to follow these instructions can result in injury
and/or equipment damage.
For more technical information, contact the factory or your
local Eaton sales representative.
xii
PowerXL DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Chapter 1—DG1 Series Overview
Chapter 1—DG1 Series Overview
This chapter describes the purpose and contents of this
manual, the receiving inspection recommendations and the
DG1 Series Open Drive catalog numbering system.
Real Time Clock Battery Activation
How to Use this Manual
Simply remove the primary drive cover, locate the RTC
battery directly below the keypad, and connect the white
2-wire connector to the receptacle on the control board.
The purpose of this manual is to provide you with information
necessary to install, set and customize parameters, start up,
troubleshoot and maintain the Eaton DG1 Series adjustable
frequency drive (AFD). To provide for safe installation and
operation of the equipment, read the safety guidelines at the
beginning of this manual and follow the procedures outlined
in the following chapters before connecting power to the
DG1 Series AFD. Keep this operating manual handy and
distribute to all users, technicians and maintenance
personnel for reference.
To activate the real time clock (RTC) functionality in the
PowerXL DG1 Series AFD, the RTC battery (already mounted
in the drive) must be connected to the control board.
Figure 1. RTC Battery Connection
Receiving and Inspection
The DG1 Series AFD has met a stringent series of factory
quality requirements before shipment. It is possible that
packaging or equipment damage may have occurred during
shipment. After receiving your DG1 Series AFD, please
check for the following:
Check to make sure that the package includes the Instruction
Leaflet (IL040016EN), Quick Start Guide (MN040006EN),
User Manual CD (CD040002EN) and accessory packet. The
accessory packet includes:
●
Rubber grommets
●
Control cable grounding clamps
●
Additional grounding screw
Inspect the unit to ensure it was not damaged during
shipment.
Make sure that the part number indicated on the nameplate
corresponds with the catalog number on your order.
Table 1. Common Abbreviations
Abbreviation
Definition
CT
Constant torque with high overload rating (150%)
VT
Variable torque with low overload rating (110%)
If the delivery does not correspond to your order, please
contact your Eaton Electrical representative.
IH
IL
High Overload (150%)
Note: Do not destroy the packing. The template printed
on the protective cardboard can be used for marking
the mounting points of the DG1 AFD on the wall or
in a cabinet.
AFD
Adjustable Frequency Drive
VFD
Variable Frequency Drive
If shipping damage has occurred, please contact and file a
claim with the carrier involved immediately.
DG1 Series VFD
Low Overload (110%)
MN040002EN—March 2014
www.eaton.com
1
Chapter 1—DG1 Series Overview
Rating Label
Figure 2. Rating Label
Contains
SN, PN,
Type, Date
Contains
EAN Code
Contains
NAED Code
Date Code: 20131118
Carton Labels (U.S. and Europe)
Same as rating label shown above.
2
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Chapter 1—DG1 Series Overview
Catalog Number System
Figure 3. Catalog Numbering System
Series
Power Part
Options
D G1 – 3 4 4D8 F B – C 21 C
Basic Naming
D = Drive
Series
G1 = General purpose
Coating of Boards
C = Coated
Phase Reference
3 = 3~ INPUT/3~ OUTPUT
Internal Brake Chopper
N = No brake chopper
B = Brake chopper
Input/Output Voltage Rating
2 = 230V (208–240V, –15%, +10%)
4 = 400V (380–500V, –15%, +10%)
5 = 575V (525–600V, –15%, +10%)
3D7 =
4D8 =
6D6 =
7D8 =
011 =
012 =
017 =
025 =
031 =
048 =
061 =
075 =
088 =
114 =
143 =
170 =
211 =
261 =
208–240V
3.7A, 0.55 kW, 0.75 hp
4.8A, 0.75 kW, 1 hp
6.6A, 1.1 kW, 1.5 hp
7.8A, 1.5 kW, 2 hp
11A, 2.2 kW, 3 hp
12.5A, 3 kW, 5 hp (VT)
17.5A, 3.7 kW, 5 hp
25A, 5.5 kW, 7.5 hp
31A, 7.5 kW, 10 hp
48A, 11 kW, 15 hp
61A, 15 kW, 20 hp
75A, 18.5 kW, 25 hp
88A, 22 kW, 30 hp
114A, 30 kW, 40 hp
143A, 37 kW, 50 hp
170A, 45 kW, 60 hp
211A, 55 kW, 75 hp
261A, 75 kW, 100 hp
Internal EMC Filter
F = Internal EMC filter
Output Current Rating (CT)
380–500V
2D2 = 2.2A, 0.75 kW, 1 hp
3D3 = 3.3A, 1.1 kW, 1.5 hp
4D3 = 4.3A, 1.5 kW, 2 hp
5D6 = 5.6A, 2.2 kW, 3 hp
7D6 = 7.6A, 3 kW, 5 hp
9D0 = 9A, 4 kW, 7.5 hp (VT)
012 = 12A, 5.5 kW, 7.5 hp
016 = 16A, 7.5 kW, 10 hp
023 = 23A, 11 kW, 15 hp
031 = 31A, 15 kW, 20 hp
038 = 38A, 18 kW, 25 hp
046 = 46A, 22 kW, 30 hp
061 = 61A, 30 kW, 40 hp
072 = 72A, 37 kW, 50 hp
087 = 87A, 45 kW, 60 hp
105 = 105A, 55 kW, 75 hp
140 = 140A, 75 kW, 100 hp
170 = 170A, 90 kW, 125 hp
205 = 205A, 110 kW, 150 hp
261 = 261A, 132 kW, 200 hp
3D3 =
4D5 =
7D5 =
010 =
013 =
018 =
022 =
027 =
034 =
041 =
052 =
062 =
080 =
100 =
125 =
144 =
208 =
DG1 Series VFD
Enclosure (IP Rating)
21 = IP21/Type 1
54 = IP54/Type 12
Display Option
C = LCD (graphical)
525–600V
3.3A, 1.5 kW, 2 hp
4.5A, 2.2 kW, 3 hp
7.5A, 3.7 kW, 5 hp
10A, 5.5 kW, 7.5 hp
13.5A, 7.5 kW, 10 hp
18A, 11 kW, 15 hp
22A, 15 kW, 20 hp
27A, 18 kW, 25 hp
34A, 22 kW, 30 hp
41A, 30 kW, 40 hp
52A, 37 kW, 50 hp
62A, 45 kW, 60 hp
80A, 55 kW, 75 hp
100A, 75 kW, 100 hp
125A, 90 kW, 125 hp
144A, 110 kW, 150 hp
208A, 160 kW, 200 hp
MN040002EN—March 2014
www.eaton.com
3
Chapter 1—DG1 Series Overview
Power Ratings and Product Selection
DG1 Series Drives—208–240 Volt
Table 2. Type 1/IP21
Frame Size
230V, 50 Hz
kW Rating (CT/IH)
230V, 50 Hz
kW Rating (VT/IL)
FR1
0.55
0.75
0.75
1.1
1
1.5
1.1
1.5
1.5
2
1.5
2.2
2
3
7.8
FR2
FR3
FR4
FR5
FR6 1
230V, 60 Hz
hp (CT/IH)
0.75
230V, 60 Hz
hp (VT/IL)
1
Current
A (CT/IH)
3.7
Current
A (VT/IL)
4.8
DG1-323D7FB-C21C
4.8
6.6
DG1-324D8FB-C21C
6.6
7.8
DG1-326D6FB-C21C
11
DG1-327D8FB-C21C
Catalog Number
2.2
3
3
—
11
12.5
DG1-32011FB-C21C
3
3.7
—
5
12.5
17.5
DG1-32012FB-C21C
3.7
5.5
5
7.5
17.5
25
DG1-32017FB-C21C
5.5
7.5
7.5
10
25
31
DG1-32025FB-C21C
7.5
11
10
15
31
48
DG1-32031FB-C21C
11
15
15
20
48
61
DG1-32048FB-C21C
15
18.5
20
25
61
75
DG1-32061FN-C21C
18.5
22
25
30
75
88
DG1-32075FN-C21C
22
30
30
40
88
114
DG1-32088FN-C21C
30
37
40
50
114
143
DG1-32114FN-C21C
37
45
50
60
143
170
DG1-32143FN-C21C
45
55
60
75
170
211
DG1-32170FN-C21C
55
75
75
100
211
261
DG1-32211FN-C21C
75
90
100
125
261
312
DG1-32261FN-C21C
230V, 60 Hz
hp (CT/IH)
0.75
230V, 60 Hz
hp (VT/IL)
1
Current
A (CT/IH)
3.7
Current
A (VT/IL)
4.8
DG1-323D7FB-C54C
Table 3. Type 12/IP54
Frame Size
230V, 50 Hz
kW Rating (CT/IH)
230V, 50 Hz
kW Rating (VT/IL)
FR1
0.55
0.75
0.75
1.1
1
1.5
4.8
6.6
DG1-324D8FB-C54C
1.1
1.5
1.5
2
6.6
7.8
DG1-326D6FB-C54C
DG1-327D8FB-C54C
FR2
FR3
FR4
FR5
FR6 1
1.5
2.2
2
3
7.8
11
2.2
3
3
—
11
12.5
DG1-32011FB-C54C
3
3.7
—
5
12.5
17.5
DG1-32012FB-C54C
3.7
5.5
5
7.5
17.5
25
DG1-32017FB-C54C
5.5
7.5
7.5
10
25
31
DG1-32025FB-C54C
7.5
11
10
15
31
48
DG1-32031FB-C54C
11
15
15
20
48
61
DG1-32048FB-C54C
15
18.5
20
25
61
75
DG1-32061FN-C54C
18.5
22
25
30
75
88
DG1-32075FN-C54C
22
30
30
40
88
114
DG1-32088FN-C54C
30
37
40
50
114
143
DG1-32114FN-C54C
37
45
50
60
143
170
DG1-32143FN-C54C
45
55
60
75
170
211
DG1-32170FN-C54C
55
75
75
100
211
261
DG1-32211FN-C54C
75
90
100
125
261
312
DG1-32261FN-C54C
Note
1 FR6 available in 2015.
4
Catalog Number
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Chapter 1—DG1 Series Overview
DG1 Series Drives—380–500 Volt
Table 4. Type 1/IP21
Frame Size
FR1
FR2
FR3
FR4
FR5
FR6 1
400V, 50 Hz
kW Rating (CT/IH)
400V, 50 Hz
kW Rating (VT/IL)
0.75
1.1
1.5
2.2
3
4
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
1.1
1.5
2.2
3
4
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
160
460V, 60 Hz
hp (CT/IH)
1
1.5
2
3
5
—
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
460V, 60 Hz
hp (VT/IL)
1.5
2
3
5
—
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
250
Current
A (CT/IH)
2.2
3.3
4.3
5.6
7.6
9
12
16
23
31
38
46
61
72
87
105
140
170
205
261
Current
A (VT/IL)
3.3
4.3
5.6
7.6
9
12
16
23
31
38
46
61
72
87
105
140
170
205
261
310
460V, 60 Hz
hp (CT/IH)
1
1.5
2
3
5
—
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
460V, 60 Hz
hp (VT/IL)
1.5
2
3
5
—
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
250
Current
A (CT/IH)
2.2
3.3
4.3
5.6
7.6
9
12
16
23
31
38
46
61
72
87
105
140
170
205
261
Current
A (VT/IL)
3.3
4.3
5.6
7.6
9
12
16
23
31
38
46
61
72
87
105
140
170
205
261
310
Catalog Number
DG1-342D2FB-C21C
DG1-343D3FB-C21C
DG1-344D3FB-C21C
DG1-345D6FB-C21C
DG1-347D6FB-C21C
DG1-349D0FB-C21C
DG1-34012FB-C21C
DG1-34016FB-C21C
DG1-34023FB-C21C
DG1-34031FB-C21C
DG1-34038FB-C21C
DG1-34046FB-C21C
DG1-34061FN-C21C
DG1-34072FN-C21C
DG1-34087FN-C21C
DG1-34105FN-C21C
DG1-34140FN-C21C
DG1-34170FN-C21C
DG1-34205FN-C21C
DG1-34261FN-C21C
Table 5. Type 12/IP54
Frame Size
FR1
FR2
FR3
FR4
FR5
FR6 1
400V, 50 Hz
kW Rating (CT/IH)
400V, 50 Hz
kW Rating (VT/IL)
0.75
1.1
1.5
2.2
3
4
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
1.1
1.5
2.2
3
4
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
160
Catalog Number
DG1-342D2FB-C54C
DG1-343D3FB-C54C
DG1-344D3FB-C54C
DG1-345D6FB-C54C
DG1-347D6FB-C54C
DG1-349D0FB-C54C
DG1-34012FB-C54C
DG1-34016FB-C54C
DG1-34023FB-C54C
DG1-34031FB-C54C
DG1-34038FB-C54C
DG1-34046FB-C54C
DG1-34061FN-C54C
DG1-34072FN-C54C
DG1-34087FN-C54C
DG1-34105FN-C54C
DG1-34140FN-C54C
DG1-34170FN-C54C
DG1-34205FN-C54C
DG1-34261FN-C54C
Note
1 FR6 available in 2015.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
5
Chapter 1—DG1 Series Overview
Replacement Parts
Table 6. Frame 1
Description
Standard keypad
Catalog Number
Catalog Number
Catalog Number
230V
480V
575V
DXG-KEY-LCD
DXG-KEY-LCD
DXG-KEY-LCD
Main control board 1
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
Control board cover
DXG-SPR-BCOVER
DXG-SPR-BCOVER
DXG-SPR-BCOVER
Type 1/IP21 standard cover
DXG-SPR-FR1CVR
DXG-SPR-FR1CVR
2
Main fan kit 1
DXG-SPR-FR1FAN
DXG-SPR-FR1FAN
2
Control fan
DXG-SPR-2FR1CF
DXG-SPR-4FR1CF
2
Main power board
DXG-SPR-2FR1MPB
DXG-SPR-4FR1MPB
2
EMI board
DXG-SPR-2FR1EB
DXG-SPR-4FR1EB
2
Middle chassis cover
DXG-SPR-FR1MCC
DXG-SPR-FR1MCC
2
Outer housing
DXG-SPR-FR1OH
DXG-SPR-FR1OH
2
UL conduit plate
DXG-SPR-FR1CPUL
DXG-SPR-FR1CPUL
2
IEC conduit plate
DXG-SPR-FR1CPIEC
DXG-SPR-FR1CPIEC
2
Catalog Number
Catalog Number
Catalog Number
230V
480V
575V
1
Notes
1 Factory recommended spare parts.
2 575V available in 2015.
Table 7. Frame 2
Description
DXG-KEY-LCD
DXG-KEY-LCD
DXG-KEY-LCD
Main control board 1
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
Control board cover
DXG-SPR-BCOVER
DXG-SPR-BCOVER
DXG-SPR-BCOVER
Type 1/IP21 standard cover
DXG-SPR-FR2CVR
DXG-SPR-FR2CVR
2
Main fan kit 1
DXG-SPR-FR2FAN
DXG-SPR-FR2FAN
2
Control fan
DXG-SPR-FR2CF
DXG-SPR-FR2CF
2
Bus capacitor
DXG-SPR-2FR2BC
DXG-SPR-4FR24BC
2
Main power board
DXG-SPR-2FR2MPB
DXG-SPR-4FR2MPB
2
EMI board
DXG-SPR-2FR2EB
DXG-SPR-4FR2EB
2
IGBT module
DXG-SPR-FR2IGBT
DXG-SPR-FR2IGBT
2
Middle chassis cover
DXG-SPR-FR2MCC
DXG-SPR-FR2MCC
2
Outer housing
DXG-SPR-FR2OH
DXG-SPR-FR2OH
2
UL conduit plate
DXG-SPR-FR2CPUL
DXG-SPR-FR2CPUL
2
IEC conduit plate
DXG-SPR-FR2CPIEC
DXG-SPR-FR2CPIEC
2
Standard keypad
1
Notes
1 Factory recommended spare parts.
2 575V available in 2015.
6
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Chapter 1—DG1 Series Overview
Table 8. Frame 3
Catalog Number
Catalog Number
Catalog Number
Description
230V
480V
575V
Standard keypad 1
DXG-KEY-LCD
DXG-KEY-LCD
DXG-KEY-LCD
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
Control board cover
DXG-SPR-BCOVER
DXG-SPR-BCOVER
DXG-SPR-BCOVER
Type 1/IP21 standard cover
DXG-SPR-FR3CVR
DXG-SPR-FR3CVR
2
Main fan kit 1
DXG-SPR-FR3FAN
DXG-SPR-FR3FAN
2
Control fan
DXG-SPR-FR34CF
DXG-SPR-FR34CF
2
Bus capacitor
DXG-SPR-FR3BC
DXG-SPR-FR3BC
2
Main power board
DXG-SPR-2FR3MPB
DXG-SPR-4FR3MPB
2
EMI board
DXG-SPR-2FR3EB
DXG-SPR-4FR3EB
2
Drive board
DXG-SPR-2FR3DB
DXG-SPR-4FR3DB
2
Output board
DXG-SPR-FR3OB
DXG-SPR-FR3OB
2
Middle chassis cover
DXG-SPR-FR3MCC
DXG-SPR-FR3MCC
2
Outer housing
DXG-SPR-FR3OH
DXG-SPR-FR3OH
2
UL conduit plate
DXG-SPR-FR3CPUL
DXG-SPR-FR3CPUL
2
IEC conduit plate
DXG-SPR-FR3CPIEC
DXG-SPR-FR3CPIEC
2
Catalog Number
Catalog Number
Catalog Number
230V
480V
575V
DXG-KEY-LCD
DXG-KEY-LCD
DXG-KEY-LCD
Main control board
1
Notes
1 Factory recommended spare parts.
2 575V available in 2015.
Table 9. Frame 4
Description
Standard keypad 1
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
Control board cover
DXG-SPR-BCOVER
DXG-SPR-BCOVER
DXG-SPR-BCOVER
Type 1/IP21 standard cover
DXG-SPR-FR4CVR
DXG-SPR-FR4CVR
2
Main fan kit 1
DXG-SPR-FR4FAN
DXG-SPR-FR4FAN
2
Control fan
DXG-SPR-FR34CF
DXG-SPR-FR34CF
2
Bus capacitor
DXG-SPR-2FR4BC
DXG-SPR-4FR24BC
2
Main power board
DXG-SPR-2FR4MPB
DXG-SPR-4FR4MPB
2
EMI board
DXG-SPR-2FR4EB
DXG-SPR-4FR4EB
2
Softstart board
DXG-SPR-2FR4SB
DXG-SPR-4FR4SB
2
IGBT module
DXG-SPR-2FR4IGBT
DXG-SPR-4FR4IGBT
2
Rectifier module
DXG-SPR-2FR4RM
DXG-SPR-4FR4RM
2
Brake chopper module
DXG-SPR-2FR4BCM
DXG-SPR-4FR4BCM
2
Middle chassis cover
DXG-SPR-FR4MCC
DXG-SPR-FR4MCC
2
Outer housing
DXG-SPR-FR4OH
DXG-SPR-FR4OH
2
UL conduit plate
DXG-SPR-FR4CPUL
DXG-SPR-FR4CPUL
2
IEC conduit plate
DXG-SPR-FR4CPIEC
DXG-SPR-FR4CPIEC
2
Main control board
1
Notes
1 Factory recommended spare parts.
2 575V available in 2015.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
7
Chapter 1—DG1 Series Overview
Table 10. Frame 5
Catalog Number
Catalog Number
Catalog Number
Description
230V
480V
575V
Standard keypad 1
DXG-KEY-LCD
DXG-KEY-LCD
DXG-KEY-LCD
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
DXG-SPR-CTRLBOARD
Control board cover
DXG-SPR-BCOVER
DXG-SPR-BCOVER
DXG-SPR-BCOVER
Type 1/IP21 standard cover
DXG-SPR-FR5CVR
DXG-SPR-FR5CVR
2
Main fan kit 1
DXG-SPR-FR5FAN
DXG-SPR-FR5FAN
2
Control fan
DXG-SPR-FR5CF
DXG-SPR-FR5CF
2
Bus capacitor
DXG-SPR-FR5BC
DXG-SPR-FR5BC
2
Main power board
DXG-SPR-2FR5MPB
DXG-SPR-4FR5MPB
2
EMI-1 board
DXG-SPR-2FR5E1B
DXG-SPR-4FR5E1B
2
EMI-2 board
DXG-SPR-2FR5E2B
DXG-SPR-4FR5E2B
2
EMI-3 board
DXG-SPR-FR5E3B
DXG-SPR-FR5E3B
2
IGBT module
DXG-SPR-FR5IGBT
DXG-SPR-FR5IGBT
2
Rectifier module
DXG-SPR-2FR5RM
DXG-SPR-4FR5RM
2
Brake chopper module
DXG-SPR-2FR5BCM
DXG-SPR-4FR5BCM
2
Middle chassis cover
DXG-SPR-FR5MCC
DXG-SPR-FR5MCC
2
Outer housing
DXG-SPR-FR5OH
DXG-SPR-FR5OH
2
UL conduit plate
DXG-SPR-FR5CPUL
DXG-SPR-FR5CPUL
2
IEC conduit plate
DXG-SPR-FR5IECCP
DXG-SPR-FR5IECCP
2
Main control board
1
Notes
1 Factory recommended spare parts.
2 575V available in 2015.
8
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Chapter 2—Engineering Considerations
Chapter 2—Engineering Considerations
Introduction
Table 11. Drive System Components
This chapter describes the most important features in the
energy circuit of a drive system that you should take into
consideration in your project planning.
Item No.
Description
1
Power grid configuration, input voltage, input frequency,
interactions with PF correction systems
2
Breakers, fuses, cable cross-sections
3
Protection of persons and animals with residual-current
protective devices
L2
4
Input contactor, disconnector
L3
5
Frequency inverter: mounting, installation; power connection;
EMC measures; circuit examples
6
Output contactor, disconnector
Figure 4. Drive System (PDS = Power Drive System)
L1
PE
RCD
7
Output reactor, dV/dT filter, sine-wave filter
8
Motor protection; thermistor (can be connected to drive directly)
9
Cable lengths, motor cables, shielding (EMC)
10
Motor and application, parallel operation of multiple motors on
a VFD, bypass circuit, DC braking
PE L1 L2 L3
CPU
7
PE U
#
8
V W
PES
M
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
9
Chapter 2—Engineering Considerations
Electrical Power Network
Input Voltage and Frequency
Input Connection and Configuration
The standardized input voltages (IEC 60038, VDE017-1) for
energy suppliers (EVU) guarantee the following conditions at
the transition points:
The DG1 Series frequency inverters can be connected and
operated with all control-point grounded AC power networks
(see IEC 60364 for more information).
Figure 5. AC Power Networks with Grounded Neutral
Point (TN- / TT Networks)
TN-S
TN-C
L1
L2
L3
N
PE
L1
L2
L3
PEN
●
Deviation from the rated value of voltage: Max. ±10%
●
Deviation in voltage phase balance: Max. ±3%
●
Deviation from rated value of the frequency: Max. ±4%
The board tolerance band of the DG1 frequency
inverter considers the rated value for European as
(EU: ULN = 230V / 400V, 50 Hz) and American as
(USA: ULN = 240V / 480V, 60 Hz) standard voltages:
●
230V, 50 Hz (EU) and 240V, 60 Hz (USA) at DG1-32_
●
400V, 50 Hz (EU) and 480V, 60 Hz (USA) at DG1-34_
For the bottom voltage value, the permitted voltage drop of
4% in the consumer circuits is also taken into account,
therefore a total of ULN –14%.
TN-C-S
TT
L1
L2
L3
N
PE
L1
L2
L3
N
The connection and operation of frequency inverters to
asymmetrically grounded TN networks (phase-grounded
delta network “Grounded Delta”, USA) or neutral point
ungrounded or high-resistance grounded (>30 ohms) IT
networks is only conditionally permissible. In these networks
above-mentioned, the internal interference suppression filter
of frequency inverter must be disconnected (unscrew the
screw marked ‘EMC’, see “Installation in IT System” on
Page 43). Then the required filtering for EMC
(electromagnetic compatibility) is no longer present (degrade
to Class T).
Measures for EMC are mandatory in a drive system in order
to meet the legal requirements for EMC and low voltage
regulations.
Good grounding measures are a prerequisite for the effective
insert of further measures such as shielding of filters.
Without respective grounding measures, further steps are
superfluous.
DG1 Series VFD
230V device class (DG1-32_): 208V –15% to 240V +10%
(177V –0% to 264V +0%)
●
400V device class (DG1-34_): 380V –15% to 500V +10%
(323V –0% to 550V +0%)
The permitted frequency range is 50/60 Hz (45 Hz –0% to
66 Hz +0%).
The frequency inverter can be applied to all types of power
networks above. If multiple frequency inverters with
single-phase supplies are to be connected, a symmetrical
distribution to the three external conductors shall be taken
into account. In addition, the total current of all single-phase
consumers is not to cause an overload of the neutral
conductor (N-conductor).
10
●
MN040002EN—March 2014
www.eaton.com
Input Voltage Balance
Due to the uneven loading on the conductor, and with the
direct connection of greater power ratings, deviations from
the ideal voltage form and asymmetrical voltages can be
caused in three-phase AC power networks. These
asymmetric divergences in the input voltage can lead to
different loading of the diodes in input rectifiers with
three-phase supplied frequency inverters, and as a result,
an advance failure of this diode.
In the project planning for the connection of three-phase
supplied frequency inverters, consider only AC power
networks that handle permitted asymmetric divergences in
the input voltage ≤ +3%.
If this condition is not fulfilled, or symmetry at the connection
location is uncertain, the use of an assigned AC choke is
recommended.
Chapter 2—Engineering Considerations
Total Harmonic Distortion (THD)
Reactive Power Compensation Devices
Non-linear consumers (loads) in an AC supply system
produce harmonic voltages that again result in harmonic
currents. These harmonic currents at the inductive and
capacitive reactances of a mains supply system produce
additional voltage drops with different values that are then
overlaid on the sinusoidal mains voltage and result in
distortions. In supply systems, this form of “noise” can give
rise to problems in an installation if the sum of the harmonics
exceeds certain limit values.
Special compensation measures on the power supply side is
not required for DG1 Series drives, which take on very little
reactive power of the fundamental harmonics from the AC
power supply network (cosw ~0.98).
Non-linear consumers (harmonics producers) include for
example:
●
Induction and arc furnaces, welding devices
●
Current converters, rectifiers and inverters, soft starters,
variable frequency drives
●
Switched-mode power supply units (computers, monitors,
lighting), uninterrupted power supply (UPS)
In the AC power networks with non-choked reactive current
compensation devices, current deviations can enable parallel
resonance and undefinable circumstances.
In the project planning for the connection of frequency
inverters to AC power networks with undefined
circumstances, please consider using AC chokes.
The THD value (THD = Total Harmonic Distortion) is defined
in standard IEC/EN 61800-3 as the ratio of the rms value of all
harmonic components to the rms value of the fundamental
frequency. It is given in percent of the total value.
THD
; U22
+ U32 + U42 + ??? Un2
U1
3 100%
U1 — fundamental component
U n — n th order harmonic component
The THD value of the harmonic distortion is stated in relation
to the rms value of the total signal as a percentage. On a
variable frequency drive, the total harmonic distortion is
around 120%.
To assist in the calculation of system harmonics, a
Harmonic Estimation Calculator Tool is available at
www.eaton.com/drives.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
11
Chapter 3—Product Overview
Chapter 3—Product Overview
Component Identification
Figure 6. Description of the DG1 Series
Features
The DG1 frequency inverter converts the voltage and
frequency of an existing AC network into a DC voltage. This
DC voltage is used to generate a three-phase AC voltage
with adjustable frequency and assigned amplitude values for
the variable speed control of three-phase asynchronous
motors.
12
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Chapter 3—Product Overview
Figure 7. Block Diagram, Elements of DG1 Frequency Inverters
Table 12. Elements of DG1 Frequency Inverters
Item No.
Description
1
Supply L1, L2 L3, PE, input supply voltage ULN = Ue at 50/60 Hz:
DG1-32: 230V class, three-phase input connection (3 AC 230V/240V)
DG1-34: 400V class, three-phase input connection (3 AC 400V/480V)
2
Internal interference suppression filter, category C2 to IEC/EN 61800-3
EMC-connection of internal interference suppression filter to PE
3
Rectifier bridge, converts the AC voltage of the electrical network into DC voltage
4
DC link with charging resistor, capacitor and switching mode power supply unit
(SMPS = Switching Mode Power Supply):
DC link voltage UDC with three-phase input connection (3 AC): UDC = 1.41 x ULN
5
Inverter. The IGBT based inverter converts the DC voltage of the DC link (UDC) into a three-phase AC voltage (U2) with variable amplitude
and frequency (f2). Sinusoidal pulse width modulation (PWM) with V/f control can be switched to speed control with slip compensation
6
Motor connection U/T1, V/T2, W/T3 with output voltage U2 (0–100% Ue) and output frequency f2 (0–400 Hz) output current (I2):
DG1-32: 3.7A to 261A
DG1-34: 2.2A to 261A
100% at an ambient temperature of 122°F (50°C) with an overload capacity of 150% for 60 s every 600 s and a starting current
of 200% for 2 s every 20 s
7
Keypad with control buttons, graphic display, control voltage, control signal terminals, micro-switches, and interface for the
PC interface module (option)
8
Three-phase asynchronous motor, variable speed control of three-phase asynchronous motor for assigned motor shaft power values (P2):
DG1-32: 0.55 kW to 75 kW (230V, 50 Hz) or 0.75 hp to 100 hp (240V, 60 Hz)
DG1-34: 0.75 kW to 150 kW (400V, 50 Hz) or 1 hp to 200 hp (460V, 60 Hz)
9
DC link—chokes, to minimize current harmonics
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13
Chapter 3—Product Overview
Selection Criteria
The frequency inverter [3] is selected according to the supply
voltage ULN of the input supply [1] and the rated current of
the assigned motor [2]. The circuit type (P/k) of the motor
must be selected according to the supply voltage [1]. The
rated output current Ie of the frequency inverter must be
greater than/equal to the rated motor current.
If you connect a motor to an operational frequency inverter,
the motor draws a multiple of its rated operational current.
When you select a frequency inverter, make sure that the
starting current plus the sum of the currents of the running
motors will not exceed the rated output current of the
frequency inverter.
Switching in the output of the frequency inverter is only
permitted with V/Hz characteristic curve control.
Figure 8. Selection Criteria
Proper Use
The DG1 frequency inverters are electrical apparatus for
controlling variable speed drives with three-phase motors.
They are designed for installation in machines or for use in
combination with other components within a machine or
system.
After installation in a machine, the frequency inverters must
not be taken into operation until the associated machine has
been confirmed to comply with the safety requirements of
Machinery Safety Directive (MSD) 89/392/EEC (meets the
requirements of EN 60204). The user of the equipment is
responsible for ensuring that the machine use complies with
the relevant EU Directives.
The CE markings on the DG1 frequency inverter confirm that,
when used in a typical drive configuration, the apparatus
complies with the European Low Voltage Directive (LVD)
and the EMC Directives (Directive 2006/95/EC and
Directive 2004/108/EC).
When selecting the drive, the following criteria must be
known:
●
Type of motor (three-phase asynchronous motor)
●
Input voltage = rated operating voltage of the motor (for
example, 3 AC ~400V)
●
Rated motor current (guide value, dependent on the circuit
type and the supply voltage)
●
Load torque (quadratic, constant)
●
Starting torque
●
Ambient temperature (rated value 122°F [50°C])
When connecting multiple motors in parallel to the output of
a frequency inverter, the motor currents are added
geometrically—separated by effective and idle current
components. When you select a frequency inverter, make
sure that it can supply the total resulting current. If
necessary, for dampening and compensating the deviating
current values, motor reactors or sinusoidal filters must be
connected between the frequency inverter and the motor.
The parallel connection of multiple motors in the output of
the frequency inverter is only permitted with V/Hz
characteristic curve control.
14
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In the described system configurations, DG1 frequency
inverters are suitable for use in public and non-public
networks.
A connection to IT networks (networks without reference to
earth potential) is permissible only to a limited extent,
because the device’s built-in filter capacitors connect the
network with the earth potential (enclosure). On earth free
networks, this can lead to dangerous situations or damage to
the device (isolation monitoring required).
To the output of the frequency inverter (terminals U, V, W)
you must not:
●
connect a voltage or capacitive loads (for example, phase
compensation capacitors)
●
connect multiple frequency inverters in parallel
●
make a direct connection to the input (bypass)
Observe the technical data and connection requirements. For
additional information, refer to the equipment nameplate or
label at the frequency inverter, and the documentation.
Any other usage constitutes improper use.
Chapter 3—Product Overview
Maintenance and Inspection
Charging the Internal DC Link Capacitors
DG1 frequency inverters are maintenance free. However,
external influences may affect the function and the lifespan
of the DG1 frequency inverter. We therefore recommend
that the devices are checked regularly and the following
maintenance measures are carried out at the specified
intervals.
After extended storage times or extended downtimes during
which no power is supplied (>12 months), the capacitors in
the internal DC link must be recharged in a controlled manner
in order to prevent damage. To do this, the DG1 variable
frequency drive must be supplied with power, with a
controlled DC power supply unit, via two mains DC bus
connection terminals. Please consult the factory for detailed
instructions.
If the DG1 frequency inverter is damaged by external
influences, contact Eaton Technical Service.
Table 13. Maintenance Measures and Intervals
Maintenance Measure
Maintenance Interval
Clean cooling vents (cooling slits)
If required
Check the fan function
6–24 months (depending
on the environment)
Filter in the switching cabinet doors
(see manufacturer specifications)
6–24 months (depending
on the environment)
Check the tightening torques of the terminals
(control signal terminals, power terminals)
Regularly
Check connection terminals and all metallic
surfaces for corrosion
6–24 months (depending
on the environment)
Storage
If the frequency inverter is stored before use, suitable
ambient conditions must be ensured at the site of storage:
●
Storage temperature: –40°F to 158°F (–40°C to 70°C)
●
Relative average air humidity: <95%, noncondensing
(EN 50178)
●
To prevent damage to the DC link capacitors, storage
times longer than 12 months are not recommended
Service and Warranty
In the unlikely event that you have a problem with your DG1
frequency inverter, please contact your local sales office.
When you call, have the following information ready:
●
the exact frequency inverter part no. (see nameplate)
●
the date of purchase
●
a detailed description of the problem that has occurred
with the frequency inverter
If some of the information printed on the nameplate is not
legible, please state only the information that is clearly
legible. This information can also be found on the cover of
the control terminals.
Information concerning the guarantee can be found in the
Eaton General Terms and Conditions of Sale.
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15
Chapter 4—Safety and Switching
Chapter 4—Safety and Switching
Fuses and Cable Cross-Sections
The fuses and wire cross-sections allocated for power-side
connections depend on the rated input current and output
current of the frequency inverter (without AC choke).
CAUTION
When selecting the cable cross-section, take the voltage
drop under load conditions into account.
The consideration of other standards (for example, VDE 0113
or VDE 0289) is the responsibility of the user.
The national and regional standards (for example VDE 0113,
EN 60204) must be observed and the necessary approvals
(for example UL) at the site of installation must be fulfilled.
When the device is operated in a UL-approved system, use
only UL-approved fuses, fuse bases, and cables.
Use power cables with insulation according to the specified
input voltages for the permanent installation. A shielded
cable is not required on the input side.
A completely (360°) shielded low impedance cable is
required on the motor side. The length of the motor cable
depends on the RFI class and must not exceed
approximately 300 ft (100m) without additional filtering.
Residual-Current Device (RCD)
RCD (Residual Current Device): Residual current device,
residual current circuit breaker (FI circuit breaker).
Residual current circuit breakers protect persons and animals
from the existence (not the origination) of impermissibly high
contact voltages. They prevent dangerous, and in some
cases deadly injuries caused by electrical accidents, and also
serve as fire prevention.
See Appendix D—Safety Instructions for UL and cUL for
details.
CAUTION
The specified minimum PE conductor cross-sections in this
manual must be maintained. The minimum size of the
protective earthing conductor must comply with the
requirements of EN 61800-5-1 and/or the local safety
regulations.
Touch currents in this frequency inverter are greater than
3.5 mA (AC). According to product standard IEC/EN 61800-5-1,
an additional equipment grounding conductor of the same
cross-sectional area as the original protective earthing
conductor must be connected, or the cross-section of the
equipment grounding conductor must be at least 10 mm2 Cu.
Choose the cross-section of the PE conductor in the motor
lines at least as large as the cross-section of the phase lines
(U, V, W).
CAUTION
This drive can cause a DC current in the protective earthing
conductor. Where a residual current-operated protective
(RCD) or monitoring (RCM) device is used for protection in
case of direct or indirect contact, only an RCD or RCM of
Type B is allowed on the supply side of this product.
Figure 9. Identification on the FI Circuit Breakers
AC/DC sensitive
(RCD, type B)
Frequency inverters work internally with rectified AC
currents. If an error occurs, the DC currents can block a type
A RCD circuit breaker from triggering and therefore disable
the protective functionality.
CAUTION
Cables and Fuses
The cross-sections of the cables and line protection fuses
used must correspond with local standards.
For an installation in accordance with UL guidelines:
●
Use UL recognized Class T fuses for the branch circuit
protection
●
Use 75°C copper wire only
●
Use UL listed conduit fittings with the same type rating
(Type 1/Type 12) as the enclosure
See Appendix D—Safety Instructions for UL and cUL for
details.
16
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Debounced inputs may not be used in the safety circuit
diagram.
Residual current circuit breakers (RCD) are only to be
installed between the AC power supply network and the
frequency inverter.
Chapter 4—Safety and Switching
Safety-relevant leakage currents can occur while handling
and when operating the frequency inverter, if the frequency
inverter is not grounded (because of a fault).
Leakage currents to ground are mainly caused by foreign
capacities with frequency inverters, between the motor
phases and the shielding of the motor cable and via the
Y-capacitors of the RFI filter. The size of the leakage current
is mainly dependent upon the:
●
length of the motor cable
●
shielding of the motor cable
●
height of the switching frequency of the inverter
●
design of the RFI filter
●
grounding measures at the site of the motor
The leakage current to ground is greater than 3.5 mA with a
frequency inverter. According to product standard IEC/EN
61800-5-1, an additional equipment grounding (PE) conductor
of the same cross-sectional area as the original protective
earthing conductor must be connected, or the cross-section
of the equipment grounding conductor must be at least
10 mm2 Cu.
Input Contactor
The input contactor enables an operational switching on and
off of the supply voltage for the frequency inverter, and
switching off in case of a fault.
The input contactor is designed based on the input current
(ILN) of the frequency inverter and the utilization category
AC-1 (IEC 60947). Input contactors and the assignment to
DG1 frequency inverters are explained in Appendix A.
While planning the project, make sure that inching operation
is not done via the input contactor of the frequency inverter
on frequency-controlled drives, but through a controller input
of the frequency inverter.
The maximum permitted operating frequency of the input
voltage with the DG1 frequency inverter is one time per
minute (normal operation).
Residual current circuit breakers must be suitable for:
●
the protection of installations with DC current component
in case of fault scenario (RCD type B)
●
high leakage currents
●
brief discharges of pulse current spikes
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17
Chapter 4—Safety and Switching
EMC Measures
Figure 10. EMC Measures
Electrical components in a system (machine) have an
interaction effect on each other. Each device not only emits
interference but is also affected by it. The interference can
be produced by galvanic, capacitive, and/or inductive
sources, or by electromagnetic radiation. In practice, the limit
between line-conducted interference and radiated emitted
interference is around 30 MHz. Above 30 MHz, cables and
conductors act like antennas that radiate electromagnetic
waves.
Low Voltage Supply Grid
1st Environment
Electromagnetic compatibility (EMC) for frequency controlled
drives (variable frequency drives) is implemented in
accordance with product standard IEC/EN 61800-3. This
includes the complete power drive system (PDS), from the
input supply to the motor, including all components, as well
as cables. This type of drive system can consist of several
individual drives.
The generic standards of the individual components in a PDS
compliant with IEC/EN 61800-3 do not apply. These
component manufacturers, however, must offer solutions
that ensure standards-compliant use.
In Europe, maintaining the EMC guidelines is mandatory.
A declaration of conformity (CE) always refers to a “typical”
power drive system (PDS). The responsibility to comply with
the legally stipulated limit values and thus the provision of
electromagnetic compatibility is ultimately the responsibility
of the end user or system operator. This operator must also
take measures to minimize or remove emission in the
environment concerned (see Figure 10). He must also use
means to increase the interference immunity of the devices
of the system.
Category C1
Category C1/C2
Low Voltage Supply Grid
2nd Environment
With their high interference immunity up to category C2,
DG1 frequency inverters are ideal for use in commercial
networks (1st environment).
Table 14. Maximum Motor Cable Length by Frame Size
without dV/dT Protected C2 Ratings
Frame Size
Maximum Cable Length (m)
FR1
100
FR2
150
FR3
150
FR4
200
FR5
200
18
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Category C3/C4
Chapter 5—Motor and Application
Chapter 5—Motor and Application
Motor Selection
Connecting Motors in Parallel
General recommendations for motor selection:
The DG1 frequency inverters allow parallel operation of
several motors using multi-pump application control mode:
●
Use three-phase powered asynchronous motors with
short-circuit rotors and surface cooling, also called inverter
motors or standard motors for the frequency-controlled
drive system (PDS). Other specifications such as external
rotor motors, slip-ring motors, reluctance motors,
synchronous or servo motors can also be run with a
frequency inverter, but normally require additional planning
and discussion with the motor manufacturer.
●
Use only motors with at least heat class F (311°F [155°C]
maximum steady state temperature).
●
Four-pole motors are preferred (synchronous speed: 1500
min–1 at 50 Hz or 1800 min–1 at 60 Hz).
●
Take the operating conditions into account for S1 operation
(IEC 60034-1).
●
When operating multiple motors in parallel on one
frequency inverter, the motor output should not be more
than three power classes apart.
●
Ensure that the motor is not over-dimensioned. If a motor
in speed control mode is under-dimensioned, the motor
rating must only be one rating level lower.
●
Multi-pump application: several motors with the same or
different rated operational data. The sum of all motor
currents must be less than the frequency inverter’s rated
operational current.
●
Multi-pump application: parallel control of several motors.
The sum of the motor currents plus the motors’ inrush
currents must be less than the frequency inverter’s rated
operational current.
Parallel operation at different motor speeds can be
implemented only by changing the number of pole pairs and/
or changing the motor’s transmission ratio.
CAUTION
Debounced inputs may not be used in the safety circuit
diagram.
If you are connecting multiple motors on one frequency
inverter, you must design the contactors for the individual
motors according to utilization category AC-3.
Selecting the motor contactor is done according to the rated
operational current of the motor to be connected.
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19
Chapter 5—Motor and Application
Parallel Connection of Several Motors to One
Frequency Inverter
Figure 11. Parallel Connection
Motor and Circuit Type
The motor’s stator winding can be connected in a star or
delta configuration, in accordance with the rated operational
data on the nameplate.
Figure 12. Example of a Motor Ratings Plate
Figure 13. Star and Delta Circuit Types
Connecting motors in parallel reduces the load resistance at
the frequency inverter output. The total stator inductance is
lower and the leakage capacity of the lines greater. As a
result, the current distortion is greater than in a single-motor
circuit. To reduce the current distortion, you should use
motor reactors (see 1 in Figure 11) in the output of the
frequency inverter.
The current consumption of all motors connected in parallel
must not exceed the frequency inverter’s rated output
current I2N.
Electronic motor protection cannot be used when operating
the frequency inverter with several parallel connected
motors. You must, however, protect each motor with
thermistors and/or overload relays.
The use of a motor protective circuit breaker at the frequency
inverter’s output can lead to nuisance tripping.
The three-phase motor with the rating plate based on
Figure 13, can be run in a star or delta connection. The
operational characteristic curve is determined by the
ratio of motor voltage and motor frequency, in this case.
87 Hz Characteristic Curve
In the delta circuit with 400V and 87 Hz, the motor shown
in Figure 13 was released with three times-fold output
(~1.3 kW).
Because of the higher thermal loading, using only the next
higher motor output according to the list (1.1 kW) is
recommended. The motor (in this example) therefore still has
1.47-fold higher output compared with the listed output
(0.75 kW).
With the 87 Hz characteristic curve, the motor also works in
the range from 50 Hz to 87 Hz with an un-attenuated field.
The pull-out torque remains at the same level as in input
operation with 50 Hz.
The heat class of the motor must be at least F in 87 Hz
operation.
20
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Chapter 5—Motor and Application
V/Hz Characteristic Curve
Figure 14. V/Hz Characteristic Curve
Table 15 shows the allocation of possible frequency
inverters depending on the input voltage and the type of
circuit.
Table 15. Assignment of Frequency Inverters to Example Motor Circuit (See Figure 14)
Frequency Inverters
DG1-323D7FB
DG1-343D3FB
DG1-344D3FB
Rated operational current
3.7A
3.3A
4.3A
Input voltage
3 AC, 230V
3 AC, 400V
3 AC, 400V
Motor circuit
Delta
Star
Delta
V/Hz characteristic curve
2
1
3
Motor current
3.5A
2.0A
3.5A
Motor voltage (ratings plate)
230V
400V
230V
Motor speed
1430 min-1
1430 min-1
2474 min-1 4
Motor frequency
50 Hz
50 Hz
87 Hz 3
Notes
1 Star connection: 400V, 50 Hz.
2 Delta connection: 230V, 50 Hz.
3 Delta connection: 400V, 87 Hz.
4 Note the permitted limit values of the motor.
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21
Chapter 5—Motor and Application
Bypass Operation
CAUTION
If you want to have the option of operating the motor with
the frequency inverter or directly from the input supply, the
input branches must be interlocked mechanically.
Debounced inputs may not be used in the safety circuit
diagram.
Switch S1 must switch only when frequency inverter T1 is at
zero current.
CAUTION
Debounced inputs may not be used in the safety circuit
diagram.
A changeover between the frequency inverter and the input
supply must take place in a voltage-free state.
WARNING
Contactors and switches (S1) in the frequency inverter
output and for the direct start must be designed based on
utilization category AC-3 for the rated operational current of
the motor.
Connecting EX Motors
The frequency inverter outputs (U, V, W) must not be
connected to the input voltage (destruction of the
device, risk of fire).
Note the following when connecting explosion-protected
motors:
●
The frequency inverter must be installed outside the
EX area.
●
Note the branch- and country-specific standards for
explosion-protected areas (ATEX 100a).
●
Note the standards and information of the motor
manufacturer regarding operation on frequency inverters—
for example, if motor reactors or sine-wave filters are
specified.
●
Temperature monitors in the motor windings (thermistor,
thermo-Click) are not to be connected directly to frequency
inverters but must be connected via an approved trigger
apparatus for EX areas.
Figure 15. Bypass Motor Control (Example)
L1 L2 L3
Q1
I> I> I>
Q11
L1 L2 L3
T1 U V W
S1
M1
M
3~
Table 16. Bypass Motor Control
Item No.
Description
1
Input/bypass contactor
2
Output contactor
22
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Chapter 6—Installation Requirements
Chapter 6—Installation Requirements
This chapter contains all of the information required to
properly install and prepare the DG1 Series VFD for
operation. The contents are listed to serve as a list of
tasks needed to complete the installation. Included in
this section are:
●
Line (mains) and motor power wiring
●
I/O control wiring
Standard Mounting Instructions
●
Select the mounting location based on requirements listed
in this chapter
●
Mounting surface must be a vertical, flat, non-flammable
surface
●
DG1 Series open drives may be mounted side-by-side or
stacked vertically, as outlined in this chapter
●
Surface must be strong enough to support the drive and
not subject to excessive motion or vibration
●
Mark the location of the mounting holes on the mounting
surface (“using the template provided on the cover of the
cardboard shipping package”,
●
Using fasteners appropriate to your VFD and mounting
surface, securely attach the VFD to the mounting surface
using all four mounting hole locations
Electrical Installation Warnings and Cautions
WARNING
Carry out wiring work only after the frequency inverter
has been correctly mounted and secured.
WARNING
Electric shock hazard—risk of injuries!
Carry out wiring work only if the unit is de-energized.
CAUTION
When mounting one unit above the other, the lower unit air
outlet must be directed away from the inlet air used by the
upper one. The clearance between the upper and lower unit
should equal C + D. See Figure 16 on next page.
1.
Measure the mounting space to ensure that it allows the
minimum space surrounding the VFD Series drive. Drive
dimensions are on Appendix C.
2.
Make sure the mounting surface is flat and strong
enough to support the drive, is not flammable, and is not
subject to excessive motion or vibration.
3.
Ensure that the minimum airflow requirements for your
drive are met at the mounting location.
4.
Mark the location of the mounting holes on the
mounting surface, using the template provided on the
cover of the cardboard shipping package.
5.
Using fasteners appropriate to your drive and mounting
surface, securely attached the drive to the mounting
surface using all four screws or bolts.
Debounced inputs may not be used in the safety circuit
diagram.
Fire hazard!
Only use cables, protective switches, and contactors that
feature the indicated permissible nominal current value.
CAUTION
Debounced inputs may not be used in the safety circuit
diagram.
According to product standard IEC/EN 61800-5-1, an
additional equipment grounding (PE) conductor of the same
cross-sectional area as the original protective earthing
conductor must be connected, or the cross-section of the
equipment grounding conductor must be at least 10 mm2 Cu.
WARNING
Mounting Dimensions
Refer to Appendix C for drive dimensions.
The components in the drive’s power section remain
energized after the supply voltage has been switched off.
After disconnecting the supply, wait at least five minutes
before removing the cover to allow the intermediate
circuit capacitors to discharge.
Pay attention to hazard warnings!
DG1 Series VFD
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23
Chapter 6—Installation Requirements
Figure 16. Mounting Space
C
B
B
A
A
D
Table 17. Space Requirements for Mounting the DG1 Series VFD and Airflow
Frame
Size
Voltage
hp (CT/IH)
FR1
230 Vac
0.75–3
0.55–2.2
3.7–11
480 Vac
1–5
0.75–3.7
2.2–7.6
FR2
FR3
FR4
FR5
FR6 3
kW 2
Amperes
575 Vac 3
2–5
1.5–3.7
3.3–7.5
230 Vac
4–7.5
3–5.5
12.5–25
480 Vac
7.5–15
5.5–11
12–23
575 Vac 3
7.5–15
5.5–11
10–18
230 Vac
10–15
7.5–11
31–48
480 Vac
20–30
15–22
31–46
575 Vac 3
20–30
15–22
22–34
230 Vac
20–30
15–22
61–88
480 Vac
40–60
30–45
61–87
575 Vac 3
40–60
30–45
41–62
230 Vac
40–60
30–45
114–170
480 Vac
75–125
55–90
105–170
575 Vac 3
75–125
55–90
80–125
230 Vac
75–100
55–75
211–261
480 Vac
150–200
110–150
205–261
575 Vac 3
150–200
110–160
144–208
A1
In (mm)
B1
In (mm)
C
In (mm)
D
In (mm)
Cooling Air
Required
CFM (m3/h)
0.79
(20)
0.79
(20)
3.94
(100)
1.97
(50)
22
(38)
1.18
(30)
1.18
(30)
6.30
(160)
2.36
(60)
55
(94)
1.97
(50)
1.97
(50)
7.87
(200)
3.15
(80)
126
(214)
3.15
(80)
3.15
(80)
11.81
(300)
3.94
(100)
153
(260)
3.15
(80)
3.15
(80)
11.81
(300)
7.87
(200)
366
(622)
3
3
3
3
3
Notes
1 Minimum clearances A and B for drives with Type 12 (IP54) enclosure is 0 mm (in).
2 kW ratings are at 400V / 50 Hz.
The above guidelines apply unless testing has been completed to validate a design outside of these recommendations.
3 FR6 and 575 Vac available in 2015.
24
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MN040002EN—March 2014
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Chapter 6—Installation Requirements
Dimensions
Approximate Dimensions in mm
Figure 17. Type 1/12 Open Drives
W4
D
W2
H1
H2
H3
W1
W3
Table 18. Mounting Drive Dimensions
Frame
Size
Voltage
hp (CT/IH) kW
FR1
230 Vac
0.75–3
0.55–2.2
Amperes
(CT/IH)
3.5–11
480 Vac
1–5
0.75–3.7
2.3–7.6
FR2
FR3
FR4
FR5
FR6 1
575 Vac 1 2–5
1.5–3.7
3.3–7.5
230 Vac
5–7.5
3–5.5
12.5–25
480 Vac
7.5–15
5.5–11
12–23
575 Vac 1 7.5–15
5.5–11
10–18
230 Vac
10–15
7.5–11
31–48
480 Vac
20–30
15–22
31–46
575 Vac 1 20–30
15–22
22–34
230 Vac
20–30
15–22
61–88
480 Vac
40–60
30–45
61–87
575 Vac 1 40–60
30–45
41–62
230 Vac
40–60
30–45
114–170
480 Vac
75–125
55–90
105–170
575 Vac 1 75–125
55–90
80–125
230 Vac
75–100
55–75
211–261
480 Vac
150–200
110–150
205–261
575 Vac 1 150–200
110–160
144–208
Approximate Dimensions in Inches (mm)
H2
H3
W1
W2
W3
W4
Ø
Weight
Lb (kg)
7.89
12.87
(200.4) (326.9)
12.28
(311.9)
11.50
(292.1)
6.02
(153.0)
4.80
(121.9)
3.94
(100.1)
3.94
(100.1)
0.28
(7.0)
14.33
(6.5)
9.63
16.50
(244.7) (419.1)
15.98
(405.9)
14.96
(380.0)
6.61
(167.8)
5.28
(134.1)
3.54
(90.0)
3.54
(90.0)
0.28
(7.0)
23.37
(10.6)
10.44 21.97
(265.1) (558.0)
21.46
(545.0)
20.43
(518.9)
8.06
(204.6)
7.24
(183.9)
4.92
(125.0)
4.92
(125.0)
0.35
(9.0)
49.82
(22.6)
11.57 24.80
(294.0) (629.9)
34.31
(617.5)
23.27
(591.1)
9.36
(237.7)
9.13
(231.9)
8.07
(205.0)
8.07
(205.0)
0.35
(9.0)
77.60
(35.2)
13.41 34.98
(340.7) (888.5)
29.65
(753.1)
27.83
(706.9)
11.34
(288.0)
11.10
(281.9)
8.66
(220.0)
8.66
(220.0)
0.35
(9.0)
154.32
(70.0)
1
1
1
1
1
1
1
1
1
D
H1
1
Note
1 FR6 and 575 Vac available in 2015.
DG1 Series VFD
MN040002EN—March 2014
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25
Chapter 6—Installation Requirements
Standard Drive Mounting
FR1 Mounting Instructions
FR2 Mounting Instructions
Step 1: Lift the drive out from the carton. Remove the
packaging.
Step 1: Lift the drive out from the carton. Remove the
packaging.
Step 2: Attach the drive to the mounting plate with four
M5x15 or 3/16 inch screws and four M5 or 3/16 inch
nuts. The opening dimensions on the mounting
plate should follow required dimensions (refer to
the drive mounting template printed on the outside
carton).
Step 2: Attach the drive to the mounting plate with four
M5x15 or 3/16 inch screws and four M5 or 3/16 inch
nuts. The opening dimensions on the mounting
plate should follow required dimensions (refer to
the drive mounting template printed on the outside
carton).
Screw: Four M5x15
or 3/16 inch
Nut: Four M5
or 3/16 inch
Screw: Four M5x15
or 3/16 inch
Nut: Four M5
or 3/16 inch
26
DG1 Series VFD
MN040002EN—March 2014
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Chapter 6—Installation Requirements
FR3 Mounting Instructions
FR4 Mounting Instructions
Step 1: Lift the drive out of the carton. Remove the
packaging.
Step 1: Lift the drive out of the carton with the cardboard.
Remove the packaging.
Step 2: Attach the drive to the mounting plate with four
M6x15 or 1/4 inch screws and four M6 or 1/4 inch
nuts. The opening dimensions on the mounting
plate should follow required dimensions (refer to
the drive mounting template printed on the outside
carton).
Step 2: Attach the drive to the mounting plate with four
M8x15 or 3/8 inch screws and four M8 or 3/8 inch
nuts. The opening dimensions on the mounting
plate should follow required dimensions (refer to
the drive mounting template printed on the outside
carton).
Screw: Four M6x15
or 1/4 inch
Nut: Four M6
or 1/4 inch
Screw: Four M8x15
or 3/8 inch
Nut: Four M8
or 3/8 inch
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27
Chapter 6—Installation Requirements
FR5 Mounting Instructions
Step 1: Remove the carton from the drive.
Step 4: Attach the drive to the mounting plate with four
M8x20 or 3/8 inch screws and four M8 or 3/8 inch
nuts with an M8 or 3/8 inch wrench. The opening
dimensions on the mounting plate should follow
required dimensions (refer to the drive mounting
template printed on the outside carton).
Step 2: Remove the four screws (used to fix the drive to the
pallet) with an M8 or 3/8 inch wrench.
Screw: Four M8x20
or 3/8 inch
Nut: Four M8
or 3/8 inch
Step 3: Use a hook to lift the drive.
28
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MN040002EN—March 2014
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Chapter 6—Installation Requirements
Power Wiring Selection
Connection Tightening Torque
Motor cable connections are made to terminals U, V, and W.
Table 19. Tightening Torque 1 2
Cable Selection: Power and Motor Leads
Frame
Size
Power Wire
In-Lb (Nm)
Ground Wire
In-Lb (Nm)
Control Wire 3
In-Lb (Nm)
FR1
230V: 12.1 (1.4)
480V/575V: 5.5 (0.6)
10 (1.1)
4.5 (0.5)
●
Use UL approved heat-resistant copper cables only
●
75°C or higher for all units rated
FR2
15.6 (1.8)
10 (1.1)
4.5 (0.5)
●
Line voltage/mains should be Class 1 wire only outside
North America
FR3
40 (4.5)
10 (1.1)
4.5 (0.5)
FR4
95 (10.7)
14 (1.6)
4.5 (0.5)
Refer to the following tables for cable sizing guidelines
FR5
354 (40)
35 (4.0)
4.5 (0.5)
FR6
Available in 2015
—
—
●
●
North America 208V to 240V: Appendix B
●
North America 380V to 500V: Appendix B
●
All other International 380V to 600V: Appendix B
Line (Mains) and Motor Cable Installation
Notes
1 Strip the motor and power cables as shown in Figure 18 on next page.
2 Both UL and IEC tools may be used.
3 Applies to strained wire, solid wire, or ferrule installations.
Table 20. Spacing Between Parallel Motor Cables
The input line and motor cables must be sized in accordance
with the rated DG1 VFD input and output current.
Cable Length
Distance Between Cables
If motor temperature sensing is used for overload protection,
the output cable size may be selected based on the motor
specifications.
Less than 164 ft (50m)
1 ft (0.3 m)
Less than 657 ft (200m)
3 ft (1.0 m)
Maximum symmetrical supply current is 100,000A RMS for
all size DG1 VFDs.
Input Fusing
Fuses are rated based on DG1 rated input and output
current. Use Class T (UL and cUL/CSA®) or type gG/gL (IEC
60269-1). Refer to Appendix B for proper fuse size selection.
Consult with Eaton Electrical for further information on fusing
requirements.
Table 21. Maximum Motor Cable Length by Frame Size
without dV/dT Protected C2 Ratings 1 2
Frame Size
Maximum Cable Length (m)
FR1
100
FR2
150
FR3
150
FR4
200
FR5
200
Notes
1 C1 protection requires external filtering. Consult factory.
b C3 protection is covered under C2 protection levels.
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29
Chapter 6—Installation Requirements
Figure 18. Input Power and Motor Cable Stripping Lengths
Table 22. Input Power and Motor Cable Stripping and Wire Lengths
Frame
Size
Power Wiring in Inches (mm)
Motor Wiring in Inches (mm)
A1
B1
C1
D1
A2
B2
C2
D2
FR1
0.39
(10)
1.77
(45)
0.39
(10)
1.38
(35)
0.39
(10)
1.77
(45)
0.39
(10)
1.38
(35)
FR2
0.59
(15)
1.77
(45)
0.59
(15)
1.77
(45)
0.59
(15)
1.57
(40)
0.59
(15)
1.57
(40)
FR3
0.59
(15)
1.57
(40)
0.59
(15)
1.97
(50)
0.59
(15)
1.57
(40)
0.59
(15)
1.97
(50)
FR4
0.98
(25)
2.56
(65)
0.98
(25)
4.72
(120)
0.98
(25)
2.56
(65)
0.98
(25)
4.72
(120)
FR5
1.10
(28)
6.10
(155)
1.10
(28)
9.45
(240)
1.10
(28)
6.10
(155)
1.10
(28)
9.45
(240)
FR6
1
1
1
1
1
1
1
1
Note
1 FR6 available in 2015.
Cable Routing
Wiring the VFD
If conduit is being used for wiring, use separate conduits for
line voltage (mains), motor cables, and all interface/control
wiring.
Refer to the table on Page 30 for maximum cable lengths by
frame size.
To meet the UL requirements, if conduit is being used for
wiring, the enclosure openings provided for conduit
connections in the field shall be closed by UL listed conduit
fittings with the same type rating (Type 1 / Type 12) as the
enclosure.
Avoid running motor cables alongside or parallel to any other
wiring. If it is necessary to run motor cables with other
wiring, then maintain spacing between motor cables and
other wiring in accordance with the table on Page 30.
30
DG1 Series VFD
MN040002EN—March 2014
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If three or more motor cables are used, each conductor must
have its own overcurrent protection.
Chapter 6—Installation Requirements
Power Wiring Notice
Power Wiring/Grounding
Do not discard the plastic bag containing the wiring
hardware.
2.
Remove power wiring protection plate. Use power/
motor cable tables on Appendix B.
1.
3.
Add attachable grounding clamps (qty 2), one on each
side of drive.
4.
Pass motor, input power wires/cables through base
wiring plate.
5.
If shielded cable is used, connect the shields of input
power and motor cables shields to ground.
6.
Wire power terminals (L1, L2, L3), motor terminal
(U, V, W), and grounding terminals per Figure 19. Power
and motor leads must be in separate conduit.
Remove the A-cover by removing (4) screws, then lifting
the A-cover away from the base.
Wiring Hardware Contents
●
European rubber grommet and flat rubber grommet
(for IP54 integrity)
●
Modification label
●
Detachable cable clamp
●
Attachable grounding strap
●
Ground strap mounting screws
To meet the UL requirements, if conduit is being used
for wiring, the enclosure openings provided for conduit
connections in the field shall be closed by UL listed
conduit fittings with the same type rating (Type 1/
Type 12) as the enclosure.
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31
Chapter 6—Installation Requirements
Rubber Grommet Installation Instructions
Step 1: Measure the outside diameter of the cable (D1)
used to connect to the drive.
Step 5: Insert the rubber grommet into the conduit plate
together with the cable.
D1 (Cable)
Step 2: Measure the outside diameter of the
rubber grommet (D2) and select a suitable
D2 (D1 ≤ D2 ≤ D1 + 2 mm).
D2 (Grommet)
Step 6: Fasten the rubber grommet and cable with a
self-locking cable tie.
Step 3: Cut the rubber grommet at the selected diameter.
D1 ≤ D2 ≤ D1 + 2 mm
Self-Locking Cable Ties
Step 4: Run the cable through the rubber grommet.
32
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MN040002EN—March 2014
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Chapter 6—Installation Requirements
Figure 19. Ground Wiring
Note: Do not wire motor leads to R+, R–. This will cause damage to the drive.
Note: Actual layout may vary slightly by frame.
Ground Wiring
Control Wiring
●
Run motor cables in separate conduit
●
DO NOT RUN CONTROL WIRES in same conduit
●
Cables sized per Appendix B
●
Provide dedicated wire for low impedance ground
between drive and motor. DO NOT USE conduit as ground
7.
Wire the control terminals following the details for the
specific option boards shown on the following pages.
CAUTION
Improper grounding could result in damage to the motor and/
or drive and could void warranty.
Note: For ease of access, the board terminals blocks can be
unplugged for wiring.
8. Wire control to the control board.
Note: Drive default is programmed for external interlock.
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33
Chapter 6—Installation Requirements
I/O Connection
●
●
Run 240 Vac and 24 Vdc control wiring in separate conduit
Communication wire to be shielded
Table 23. I/O Connection
SW1
AI1 0–10V
AI2 SW1
AI2 SW2
AI2 0–20 mA
AI2 0–20 mA
AI2 0–10V
AI2 10–10V
SW2
Res
On
Off
i
34
(RS-485 matching resistor)
Pin
Signal Name Signal
Default Setting
Description
1
+10 V
Ref. Output Voltage
—
10 Vdc Supply Source
2
AI1+
Analog Input 1
0–10 V
Voltage Speed Reference (Programmable to 4 mA to 20 mA)
3
AI1–
Analog Input 1 Ground
—
Analog Input 1 Common (Ground)
4
AI2+
Analog Input 2
4 mA to 20 mA
Current Speed Reference (Programmable to 0–10V)
5
AI2–
Analog Input 2 Ground
—
Analog Input 2 Common (Ground)
6
GND
I/O Signal Ground
—
I/O Ground for Reference and Control
7
DIN5
Digital Input 5
Preset Speed B0
Sets frequency output to Preset Speed 1
8
DIN6
Digital Input 6
Preset Speed B1
Sets frequency output to Preset Speed 2
9
DIN7
Digital Input 7
Emergency Stop (TI–)
Input forces VFD output to shut off
10
DIN8
Digital Input 8
Force Remote (TI+)
Input takes VFD from Local to Remote
11
CMB
DI5 to DI8 Common
Grounded
Allows source input
12
GND
I/O Signal Ground
—
I/O Ground for Reference and Control
13
24V
+24 Vdc Output
—
Control voltage output (100 mA max.)
14
DO1
Digital Output 1
Ready
Shows the drive is ready to run
15
24Vo
+24 Vdc Output
—
Control voltage output (100 mA max.)
16
GND
I/O Signal Ground
—
I/O Ground for Reference and Control
17
AO1+
Analog Output 1
Output Frequency
Shows Output frequency to motor 0–60 Hz (4 mA to 20 mA)
18
AO2+
Analog Output 2
Motor Current
Shows Motor current of motor 0–FLA (4 mA to 20 mA)
19
24Vi
+24 Vdc Input
—
External control voltage input
20
DIN1
Digital Input 1
Run Forward
Input starts drive in forward direction (start enable)
21
DIN2
Digital Input 2
Run Reverse
Input starts drive in reverse direction (start enable)
22
DIN3
Digital Input 3
External Fault
Input causes drive to fault
23
DIN4
Digital Input 4
Fault Reset
Input resets active faults
24
CMA
DI1 to DI4 Common
Grounded
Allows source input
25
A
RS-485 Signal A
—
Fieldbus Communication (Modbus, BACnet)
26
B
RS-485 Signal B
—
Fieldbus Communication (Modbus, BACnet)
27
R3NO
Relay 3 Normally Open
At Speed
Relay output 3 shows VFD is at Ref. Frequency
28
R1NC
Relay 1 Normally Closed
Run
Relay output 1 shows VFD is in a run state
29
R1CM
Relay 1 Common
30
R1NO
Relay 1 Normally Open
31
R3CM
Relay 3 Common
At Speed
Relay output 3 shows VFD is at Ref. Frequency
32
R2NC
Relay 2 Normally Closed
Fault
Relay output 2 shows VFD is in a fault state
33
R2CM
Relay 2 Common
34
R2NO
Relay 2 Normally Open
DG1 Series VFD
MN040002EN—March 2014
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Chapter 6—Installation Requirements
Figure 20. Terminal Block Layout
Table 24. I/O Specifications
Item
Specification
Analog Input 1
Selectable for either Voltage or Current reference signal
0 to 10V, 0 (4) to 20 mA; Ri – 250 ohm differential
Analog Input 2
Selectable for either Voltage or Current reference signal
0 to 10V, –10 to 10V, 0 (4) to 20 mA; Ri – 250 ohm differential
Digital inputs (8)
Positive or negative logic; 18 to 30 Vdc, one input can be used as thermistor input
+24V output
Auxiliary Voltage, +24V ±15%, total max. 250 mA on board (include optional cards)
+10 VREF
Output Reference Voltage, +10V +3%, max. load 10 mA
Analog Outputs
0 (4) to 20 mA; RL max. 500 ohm
0 to 10V, 10 mA
Digital Output
Open collector output, 50 mA/48V for CE, 50 mA/36V for UL
Relay Outputs (3)
Programmable relay outputs: 2 x Form C (Relay 1 and Relay 2) and 1 x Form A (Relay 3),
Relay 3 can be used as thermistor output
Switching capacity: 24 Vdc/6A, 48 Vdc/2A, 240 Vac/6A, 125 Vdc/0.4A
DG1 Series VFD
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35
Chapter 6—Installation Requirements
Figure 21. Basic Internal Control Wiring Diagram
36
DG1 Series VFD
MN040002EN—March 2014
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Chapter 6—Installation Requirements
Control Board
The main DG1 Series VFD consists of a main control board,
control I/O connections block and two slots for extra option boards.
Figure 22. DG1 Series Adjustable Frequency Drive
Connect DSP Part
to Power Board
Fan Power Wire
Keypad
STO
Connect MCU Part
to Power Board
1
AI Mode Selection
2
ON
3
Battery (Standard)
RJ45 EtherNet/IP, BACnet,
IP Modbus TCP
Optional Card A
Optional Card B
Control I/O
Terminals
ON
1
RS-485 Terminating
Resistor
Removable
MOV Screw
Removable
EMC Screw
Line Ground
Clamp Location
Motor Ground
Clamp Location
Line Ground
Clamp Location
Grounding
Strap Location
Grounding
Strap Location
Line Side
Motor
Control Wiring
●
●
All control I/O wiring must be segregated from line (mains)
and motor cabling
Control wiring shall be shielded twisted pairs to meet
EMC levels required by IEC/EN 61800-3 (2004)
●
Run 240 Vac and +24 Vdc control I/O in separate conduit
●
Control I/O terminals must be tightened to 4.5 in-lb (0.5 Nm)
●
Wiring or ferrule size: 28~12 (Sol) AWG, 30~12 (Str) AWG,
or 0.2~2.5 mm2
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37
Chapter 6—Installation Requirements
Safe Torque Off (STO)
Connection to Power Section
The PowerXL DG1 includes Safe Torque Off (STO)
functionality as standard and provides:
Figure 24 shows the general connections for the frequency
inverter in the power section.
●
Isolation from the control board will stop IGBT from firing
●
Functional Safety SIL1 Certification: IEC/EN 61800-5-2 and
DIN EN ISO 13849 Category 1, Level C
●
Higher category levels achievable with safety relays
Three-Phase Input Connection
Figure 24. Connection to Power Section
Line
Figure 23. Thermistor STO Wiring Diagram
Motor
Terminal Designations in the Power Section
38
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MN040002EN—March 2014
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●
L1, L2, L3: Connection terminals for the supply voltage
(input, input voltage)
●
U, V, W: Connection terminals for the three-phase line to
the AC motor (output, frequency inverter)
●
PE: Connection for protective ground (reference potential).
PES with mounted cable routing plate for shielded cables
Chapter 6—Installation Requirements
Ground Connection
Checking the Cable and Motor Insulation
The ground connection is connected directly with the cable
clamp plates.
1.
The shielded cables between the frequency inverter and the
motor should be as short as possible. Connect the shielding
on both ends and over a large surface area with protective
ground PES (Protective Earth Shielding). You can connect the
shielding of the motor cable directly to the cable clamp plate
(360 degrees coverage) with the protective ground.
The frequency inverter must always be connected to the
ground potential via a grounding cable (PE).
2.
Figure 25. Grounding
Check the motor cable insulation as follows:
●
Disconnect the motor cable from terminals U, V and
W of the DG1 Series drive and from the motor
●
Measure the insulation resistance of the motor cable
between each phase conductor as well as between
each phase conductor and the protective ground
conductor
●
The insulation resistance must be >1M ohm
Check the input power cable insulation as follows:
●
Disconnect the input power cable from terminals
L1/N, L2/N and L3 of the DG1 Series drive and from
the utility line feeder
●
Measure the insulation resistance of the input power
cable between each phase conductor as well as
between each phase conductor and the protective
ground conductor
●
The insulation resistance must be >1M ohm
(FR1–FR4)
No. 2 Phillips
(FR5)
No. 3 Phillips
(FR1–FR3)
M4, 10 in-lb (1.1 Nm)
(FR4)
M4, 14 in-lb (1.6 Nm)
PE
(FR5)
M6, 35 in-lb (4.0 Nm)
15
3.
Check the motor insulation as follows:
(FR1–FR3)
●
Disconnect the motor cable from the motor and open
any bridging connections in the motor connection box
(FR4, FR5)
●
Measure the insulation resistance of each motor
winding. The measurement voltage must equal at
least the motor nominal voltage but not exceed 1000V
●
The insulation resistance must be >1M ohm
25
CAUTION
Before connecting the AC drive to mains make sure that the
EMC protection class settings of the drive are appropriately
made.
Note: After having performed the change write “EMC level
modified” on the sticker included in the DG1 delivery
(see Figure 26) and note the date. Unless already
done, attach the sticker close to the name plate of the
AC drive.
Product Modified Sticker
Figure 26. Product Modified Sticker
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
39
Chapter 7—EMC Installation
Chapter 7—EMC Installation
The responsibility to meet the local system EMC limit values
and electromagnetic compatibility requirements is the
responsibility of the end user or the system operator. This
operator must also take measures to minimize or remove
emissions in the environment concerned (see figure on
Page 41). He must also use means to increase the
interference immunity of the system devices.
In a drive system (PDS) with frequency inverters, you should
take measures for electromagnetic compatibility (EMC) while
doing your planning, because changes or improvements to
the installation site, which are required in the installation or
while mounting, are normally associated with additional
higher costs.
The technology and system of a frequency inverter cause the
flow of high frequency leakage current during operation. All
grounding measures must therefore be implemented with
low impedance connections over a large surface area.
Install the frequency inverter as directly as possible (without
spacers) on a metal plate (mounting plate).
Route input and motor cables in the switch cabinet as close
to the ground potential as possible. This is because free
moving cables act as antennas.
When laying HF cables (for example, shielded motor cables)
or suppressed cables (for example, input supply cables,
control circuit and signal cables) in parallel, a minimum
clearance of 11.81 in (300 mm) should be ensured in order to
prevent the radiation of electromagnetic energy. Separate
cable routing should also be ensured when large voltage
potential differences are involved. Any necessary crossed
cabling between the control signal and power cables should
always be implemented at right angles (90 degrees).
Never lay control or signal cables in the same duct as power
cables. Analog signal cables (measured, reference and
correction values) must be shielded.
With leakage currents greater than 3.5 mA, in accordance
with VDE 0160 or EN 61800-5-1, either
●
the protective conductor must have a cross-section of at
least 10 mm2
●
the protective conductor must be open-circuit monitored,
and the supply must be automatically disconnected in case
of discontinuity of the protective earthing conductor, or
●
the second protective conductor must be fitted.
For an EMC-compliant installation, we recommend the
following measures:
Earthing
The ground connection (PE) in the cabinet should be
connected from the input supply to a central earth point
(mounting plate). All protective conductors should be routed
in star formation from this earth point and all conductive
components of the PDS (frequency inverter, motor reactor,
motor filter, main choke) are to be connected.
Avoid ground loops when installing multiple frequency
inverters in one cabinet. Make sure that all metallic devices
that are to be grounded have a broad area connection with
the mounting plate.
●
Installation of the frequency inverter in a metallic,
electrically conducting enclosure with a good connection
to earth
●
Shielded motor cables (short cable lengths)
Screen Earth Kit
●
Ground all conductive components and housings in a drive
system using as short a line as possible with the greatest
possible cross-section (Cu-braid)
Cables that are not shielded work like antennas (sending,
receiving). Make sure that any cables that may carry
disruptive signals (for example, motor cables) and sensitive
cables (analog signal and measurement values) are shielded
apart from one another with EMC-compatible connections.
EMC Measures in the Control Panel
For EMC-compatible installation, connect all metallic parts of
the device and the switching cabinet together over broad
surfaces and so that high-frequencies will be conducted.
Mounting plates and cabinet doors should make good
contact and be connected with short HF-braided cables.
Avoid using painted surfaces (anodized, chromized). An
overview of all EMC measures is provided in the figure on
Page 41.
40
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MN040002EN—March 2014
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The effectiveness of the cable shield depends on a good
shield connection and a low shield impedance.
Use only shields with tinned or nickel-plated copper braiding.
Braided steel shields are unsuitable.
Control and signal lines (analog, digital) should always be
grounded on one end, in the immediate vicinity of the supply
voltage source (PES).
Chapter 7—EMC Installation
Installation Requirements
Figure 27. EMC-Compliant Setup—460/480 Vac
Notes
1 Power cable: L1, L2, L3 and U, V, W.
2 Control and signal lines: 1 to 36, fieldbus connection Large-area connection of all metallic control panel components. Mounting surfaces of frequency inverter
and cable shielding must be free from paint. Connect the cable shielding in the output of the frequency inverter with a large surface area contact to the ground
potential (PES). Large-area cable shield contacts with motor. Large-area earth connection of all metallic parts.
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41
Chapter 7—EMC Installation
International EMC Protection Cable
Requirements
Table 25. 1st Environment 2nd Environment EMC Levels
According to EN 61800-3 (2004)
The screened cables between the variable frequency drive
and the motor should be as short as possible.
●
●
●
●
Connect the screening, on both sides and across a large
area (360° overlap), to the protective earth (PE). The power
screening protective earth (PES) connection should be in
the immediate proximity of the variable frequency drive
and directly on the motor terminal box.
Prevent the screening from becoming unbraided, e.g., by
pushing the opened plastic sheath over the end of the
screening or with a rubber grommet on the end of the
screening. As an alternative, in addition to a broad area
cable clip, you can also twist the shielding braid at the end
and connect to protective ground with a cable clip. To
prevent EMC disturbance, this twisted shielding
connection should be made as short as possible
Screened three- or four-wire cable is recommended for the
motor cables. The green/yellow line of a four-wire cable
connects the protective ground connections from the
motor and the variable frequency drive and therefore
minimizes the equalizing current loads on the shielding
braid.
If there are additional subassemblies in a motor feeder
(such as motor contactors, overload relays, motor reactor,
sinusoidal filters or terminals), the shielding of the motor
cable can be interrupted close to these subassemblies and
connected to the mounting plate (PES) with a large area
connection.
Free or non-screened connection cables should not be any
longer than about 300 mm.
Cable Type
Category C2
Category C3
Level T
Line voltage/mains
1
1
1
Motor cable
3
2
2
Control cable
4
4
4
1
Note
1 360° earthing of the shield with cable glands in motor end needed for
EMC Level C2.
Table 26. Control Wiring Requirements
Item
Directive
Product
IEC 61800-2
Safety
UL 508C, IEC / EN 61800-5-1
EMC (at default Immunity: EN / IEC 61800-3, 2nd environment
settings)
Radiated emissions: EN / IEC 61800-3 (Transient Testing
included), 1st environment
Conducted emissions: EN / IEC 61800-3
Category C1: is possible with external filter connected to
drive. Please consult factory
Category C2: with internal filter maximum of 10m motor
cable length
Category C3: with internal filter maximum of 50m motor
cable length
Table 27. Cable Categories
Cable
Category
Description
(All cables are rated for the specific operating voltage)
1
Intended for fixed installation
2
Symmetrical power cable equipped with a concentric protection
wire.
3
Symmetrical power cable with compact low-impedance shield.
Recommended cable transfer impedance of 1–30 MHz max.
See figure below.
4
Screened cable equipped with compact low-impedance shield
Figure 28. Cable Description
PE Conductor
and Shield
PE Conductor
Shield
42
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Chapter 7—EMC Installation
Installation in Corner-Grounded Network
Corner grounding is allowed for all the drive types.
Figure 29. Locations of the EMC Screw in
Frame 1, Frame 2, Frame 3 and Frame 4
In these circumstances the EMC protection class must be
changed to level C4 following the instructions below.
Installation in IT System
If your supply network is an IT (impedance-grounded) system
but your AC drive is EMC-protected according to class C2
you need to modify the EMC protection of the AC drive to
EMC level C4. This is done by removing the built-in EMC
Screw with a simple procedure described below:
WARNING
Do not perform any modifications on the AC drive when
it is connected to mains.
WARNING
Electric shock hazard—risk of injuries! Carry out wiring
work only if the unit is de-energized.
After disconnecting the supply, wait at least five minutes
before removing the cover to allow the intermediate
circuit capacitors to discharge.
Figure 30. Locations of the EMC Screws in Frame 5
WARNING
Failure to follow these instructions will result in death or
serious injury.
Frame 1 to Frame 5
Remove the main cover of the AC drive (see Figure 30) and
locate the screw jumper connecting the built-in RFI-filters to
ground. Remove the screw jumper to disconnect the EMC
protection. Once the screw is removed, it can be
reconnected to re-engage the EMC protection.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
43
Appendix A—Technical Data and Specifications
Appendix A—Technical Data and Specifications
Table 28. PowerXL Series—DG1
Attribute
Description
Specification
Input ratings
Input voltage Uin
208V to 240V, 380V to 500V, 525V to 600V, –15 to 10%
Input frequency
50 Hz to 60 Hz (variation up to 45 Hz to 66 Hz)
Connection to power
Once per minute or less
Starting delay
3 s (FR1 to FR2), 4 s (FR3), 5 s (FR4), 6 s (FR5)
Short-circuit withstand rating
100 kAIC
Output voltage
0 to Uin
Continuous output current
IL: ambient temperature maximum 40°C, up to 60°C with derating, overload 1.1 x IL (1 min./10 min.)
IH: ambient temperature maximum 50°C, up to 60°C with derating, overload 1.5 x IH (1 min./10 min.)
Overload current
150% respectively 110% (1 min./10 min.)
Initial output current
200% (2 s/20 s)
Output frequency
0–400 Hz (standard)
Frequency resolution
0.01 Hz
Control methods
Frequency control
Speed control
Open-loop speed control
Open-loop torque control
Switching frequency
Range:
FR1–3: 1 kHz to 12 kHz
FR4–5: 1 kHz to 10 kHz
Defaults:
FR1–3: 4 kHz (IH), 6 kHz (IL)
FR4–5: 3.6 kHz
Automatic switching frequency derating in case of overload.
Frequency reference
Analog input: resolution 0.1% (10-bit), accuracy +1%
Panel reference: resolution 0.01 Hz
Field weakening point
20 Hz to 400 Hz
Output ratings
Control characteristics
Ambient conditions
Acceleration time
0.1 s to 3000 s
Deceleration time
0.1 s to 3000 s
Braking torque
DC brake: 30% x Motor Rated Torque (Tn) (without brake chopper)
Dynamic braking (with optional brake chopper using an external brake resistor):
100% continuous maximum rating
Ambient operating temperature
–10°C (no frost) to +50°C, up to +60°C with derating (CT)
–10°C (no frost) to +40°C, up to +55°C with derating (VT)
Storage temperature
–40°C to +70°C
Relative humidity
0–95% RH, noncondensing, non-corrosive
Air quality:
Chemical vapors
Mechanical particles
Tested according to IEC 60068-2-60 Test Key:
Flowing mixed gas corrosion test, Method 1 (H2S [hydrogen sulfide] and SO2 [sulfur dioxide])
Designed according to:
IEC 60721-3-3, unit in operation, class 3C2
IEC 60721-3-3, unit in operation, class 3S2
Altitude
100% load capacity (no derating) up to 3280 ft (1000 m); 1% derating for each 328 ft (100 m) above
3280 ft (1000 m); max. 9842 ft (3000 m) (2000 m for corner grounded earth main systems)
Vibration:
EN 61800-5-1
EN 60668-2-6
5–150 Hz
Displacement amplitude: 1 mm (peak) at 5 Hz to 15.8 Hz (FR1–FR5)
Maximum acceleration amplitude: 1g at 15.8 Hz to 150 Hz (FR1–FR5)
●
●
●
●
44
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Appendix A—Technical Data and Specifications
Table 28. PowerXL Series—DG1, continued
Attribute
Description
Specification
Ambient conditions,
continued
Shock:
ISTA 1 A
EN 60068-2-27
Storage and shipping: maximum 15 g, 11 ms (in package)
Overvoltage
Overvoltage Category III
Pollution degree
Pollution Degree 2
Enclosure class
IP21/Type 1 standard in entire kW/hp range
IP54/Type 12 option
Note: Keypad or keypad hole plug required to be mounted in drive for IP54/Type 12 rating
●
●
Standards
Immunity
Fulfills EN 61800-3 (2004), first and second environment
MTBF
FR1: 165,457 hours
FR2: 134,833 hours
FR3: 102,515 hours
FR4: 121,567 hours
FR5: 108,189 hours
FR6: Available in 2015
Safety
UL 508C, CSA C22.2 No. 274-13 and EN 61800-5-1
EMC
+EMC2: EN 61800-3 (2004), Category C2
The drive can be modified for IT networks and corner grounding TN system
Electrostatic discharge
Second environment, IEC 61000-4-2, 4 kV CD or 8 kV AD, Criterion B
Fast transient burst
Second environment, IEC 61000-4-4, 2 kV/5 kHz, Criterion B
Dielectrical strength
Primary to secondary: 3600 Vac/5100 Vdc
Primary to earth: 2000 Vac/2828 Vdc
Approvals
EN 61800-5-1 (2007), CE, UL and cUL (see nameplate for more detailed approvals)
EtherNet/IP, Modbus® TCP, Modbus RTU, BACnet
Fieldbus connections
Safety/protections
Overvoltage protection
Yes
Overvoltage trip limit
240V drives: 456V
480V drives: 911V
Undervoltage protection
Yes
Undervoltage trip limit
240V drives: 211V
480V drives: 370V
Earth fault protection
Yes
Input phase supervision
Yes
Motor phase supervision
Yes
Overcurrent protection
Yes
Unit overtemperature protection Yes
Motor overload protection
Yes
Motor stall protection
Yes
Motor underload protection
Yes
DC bus overvoltage control
Yes
Short-circuit protection of 24V
reference voltages
Yes
Surge protection
Yes (differential mode 2 kV; common mode 4 kV)
Common coated boards
Yes (prevents corrosion)
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
45
Appendix B—Installation Guidelines
Appendix B—Installation Guidelines
Cable and Fuse Sizing
See Page 30 for cable stripping guidelines.
Table 29. North America Cable and Fuse Sizes—208 Vac to 240 Vac Ratings
NEC
Wire Size (AWG)
Terminal
Connection Size
(AWG)
Line and
Motor
Ground
Line and
Motor
Ground
Frame
Size
Amp
Suffix
NEC
208V Input 208V Input Motor Amp
Current
Rating
Current
(VT/IL)
at 230V
(CT/IH)
FR1
3D7
3.2
4.4
4.2
4.6
3.7
4.8
10
14
14
24–10
18–10
4D8
4.4
6.1
6.0
6.6
4.8
6.6
10
14
14
24–10
18–10
6D6
6.1
7.2
6.8
7.5
6.6
7.8
10
14
14
24–10
18–10
FR2
FR3
FR4
FR5
FR6
NEC
Motor Amp Current
Rating
(CT/IH)
at 50°C
at 208V
Current
(VT/IL)
at 40°C
Fuse
Rating
(Class T)
7D8
7.2
10.2
9.6
10.6
7.8
11
15
14
14
24–10
18–10
011
10.2
11.6
—
—
11
12.5
15
12
14
24–10
18–10
012
10.2
16.3
15.2
16.7
12.5
17.5
20
10
12
20–6
12–6
017
16.2
23.2
22
24.2
17.5
25
30
8
10
20–6
12–6
025
23.1
29
28
30.8
25
31
35
8
10
20–6
12–6
031
28.7
44.2
42
46.2
31
48
60
6
10
6–2
14–4
048
44.4
56
54
59.4
48
61
80
4
8
6–2
14–4
061
56.4
64.6
68
74.8
61
75
100
3
8
6–1/0
10–1/0
075
69.4
78
80
88
75
88
110
2
6
6–1/0
10–1/0
088
81.4
94.3
104
114
88
114
125
1/0
6
6–1/0
10–1/0
114
105.5
129
130
143
114
143
175
3/0
6
1/0–350
kcmil
8–250
kcmil
143
132.3
157
154
169
143
170
200
4/0
6
1/0–350
kcmil
8–250
kcmil
170
157.3
189
192
211
170
211
250
300
4
1/0–350
kcmil
8–250
kcmil
211
195.2
4
248
261
211
261
4
4
3
4
4
261
241.4
4
312
312
261
312
4
4
3
4
4
Notes
1 Line and motor cable size is selected according to UL508C Table 40.3 for copper conductor rated 75°C. Use only with copper wire rated 75°C here.
Size requirements for other different wire types are defined in the National Electrical Code, ANSI/NFPA 70.
2 Earthing conductor size is determined by the maximum overcurrent device rating used ahead of the drive according to UL508C Table 6.4.
3 If power cubes or bypass are used, a UL recognized Class T fuse is recommended.
4 Available in 2015.
46
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Appendix B—Installation Guidelines
Table 30. International Cable and Fuse Sizes—208 Vac to 240 Vac Ratings
208V Input
Current
(VT/IL)
Current
(CT/IH)
at 50°C
Current
(VT/IL)
at 40°C
Fuse
Rating
(gG/gL)
Mains and
Motor Cable
Cu (mm2)
Frame
Size
Amp
Suffix
208V Input
Current
(CT/IH)
FR1
3D7
3.2
4.4
3.7
4.8
6
4D8
4.4
6.1
4.8
6.6
6D6
6.1
7.2
6.6
7D8
7.2
10.2
011
10.2
012
FR2
FR3
FR4
FR5
FR6
Terminal Cable Size
Main Terminal
Cu (mm2)
Earth Terminal
Cu (mm2)
3*1.5+1.5
0.2–6 solid or
0.2–4 stranded
0.75–6
10
3*1.5+1.5
0.2–6 solid or
0.2–4 stranded
0.75–6
7.8
16
3*1.5+1.5
0.2–6 solid or
0.2–4 stranded
0.75–6
7.8
11
16
3*1.5+1.5
0.2–6 solid or
0.2–4 stranded
0.75–6
11.6
11
12.5
16
3*1.5+1.5
0.2–6 solid or
0.2–4 stranded
0.75–6
10.2
16.3
12.5
17.5
20
3*4+4
0.5–16
4–16
017
16.2
23.2
17.5
25
32
3*4+4
0.5–16
4–16
025
23.1
29
25
31
32
3*6+6
0.5–16
4–16
031
28.7
44.2
31
48
50
3*16+16
16–35
2.5–25
048
44.4
56
48
61
63
3*16+16
16–35
2.5–25
061
56.4
64.6
61
75
80
3*25+16
16–50
6–50
075
69.4
78
75
88
100
3*35+16
16–50
6–50
088
81.4
94.3
88
114
125
3*50+25
16–50
6–50
114
105.5
129
114
143
160
3*70+35
50–185
10–120
143
132.3
157
143
170
200
3*95+50
50–185
10–120
170
157.3
189
170
211
250
3*150+95
50–185
10–120
211
195.2
4
211
261
4
4
4
4
261
241.4
4
261
312
4
4
4
4
Notes
1 Line and motor cable size is selected according to IEC60364–5–52:2009 Table B.52.4 for copper conductor with PVC insulation with a wiring condition of ambient
temperature 30°C in air and an installation method of “B2” (cables in conduit and cable trunking systems). For other wiring conditions, please refer to the
standard of IEC60364–5–52:2009 for suitable cable sizes.
2 Earthing conductor size is determined by the cross–sectional area of phase conductors according to IEC/EN61800–5–1:2007 Table 5. So if phase conductor size
is changed, earthing conductor size should also be changed accordingly.
3 If power cubes or bypass are used, a Class gG/gL fuse is recommended.
4 Available in 2015.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
47
Appendix B—Installation Guidelines
Table 31. North America Cable and Fuse Sizes—440 Vac to 500 Vac Ratings
NEC
Wire Size (AWG)
Terminal Connection
Size (AWG)
Line and
Motor
Ground
Line and
Motor
Ground
Frame
Size
Amp
Suffix
400V Input 400V Input NEC Motor
Current
Amp Rating
Current
(VT/IL)
at 460V
(CT/IH)
Current
(CT/IH)
at 50°C
Current
(VT/IL)
at 40°C
Fuse
Rating
(Class T)
FR1
2D2
2.0
3.1
3.0
2.1
3.0
10
14
14
30–10
18–10
3D3
3.1
4
3.4
3.0
3.4
10
14
14
30–10
18–10
4D3
4.0
5.2
4.8
3.4
4.8
10
14
14
30–10
18–10
5D6
5.2
7.1
7.6
4.8
7.6
10
14
14
30–10
18–10
7D6
7.1
8.4
—
7.6
9
15
14
14
30–10
18–10
9D0
8.4
11.2
11
9
12
15
14
14
30-10
18–10
012
11.2
15
14
11
14
20
12
12
20–6
12–6
016
14.9
21.5
21
14
21
30
10
10
20–6
12–6
023
21.4
29
27
21
27
35
8
10
20–6
12–6
031
28.8
35.2
34
27
34
50
8
10
6–2
14–4
038
35.3
42.6
40
34
40
60
6
10
6–2
14–4
FR2
FR3
FR4
FR5
FR6
046
42.8
55.7
52
40
52
80
4
8
6–2
14–4
061
56.7
65.7
65
52
65
100
4
8
6–1/0
10–1/0
072
66.9
79.4
77
65
77
110
3
6
6–1/0
10–1/0
087
80.9
97
96
77
96
125
1
6
6–1/0
10–1/0
105
97.6
129
124
96
124
175
3/0
6
1/0–350 kcmil
8–250 kcmil
140
130.1
157
156
124
156
200
3/0
6
1/0–350 kcmil
8–250 kcmil
170
158.0
189
180
156
180
250
250 kcmil
4
1/0–350 kcmil
8–250 kcmil
205
190.6
4
240
180
240
350
4
3
4
4
261
4
4
302
240
302
400
4
3
4
4
Notes
1 Line and motor cable size is selected according to UL508C Table 40.3 for copper conductor rated 75°C. Use only with copper wire rated 75°C here.
Size requirements for other different wire types are defined in the National Electrical Code, ANSI/NFPA 70.
2 Earthing conductor size is determined by the maximum overcurrent device rating used ahead of the drive according to UL508C Table 6.4.
3 If power cubes or bypass are used, a UL recognized Class T fuse is recommended.
4 Available in 2015.
48
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Appendix B—Installation Guidelines
Table 32. International Cable and Fuse Sizes—380 Vac to 440 Vac Ratings
400V Input
Current
(CT/IH)
400V Input
Current
(VT/IL)
Current
(CT/IH)
at 50°C
Current
(VT/IL)
at 40°C
Fuse
Rating
(gG/gL)
Terminal Cable Size
Mains and Motor
Cable Cu (mm2)
Main Terminal
Cu (mm2)
Earth Terminal
Cu (mm2)
6
3*1.5+1.5
3*1.5+1.5
0.2–6 solid or
0.2–4 stranded
0.75–6
6
Frame
Size
Amp
Suffix
FR1
2D2
2.0
3.1
2.2
3.3
3D3
3.1
4
3.3
4.3
4D3
4.0
5.2
4.3
5.6
10
3*1.5+1.5
0.75–6
5D6
5.2
7.1
5.6
7.6
16
3*1.5+1.5
0.75–6
7D6
7.1
8.4
7.6
9
16
3*1.5+1.5
0.75–6
9D0
8.4
11.2
9
12
16
3*1.5+1.5
0.75–6
012
11.2
15
12
16
20
3*4+4
0.5–16
4–16
016
14.9
21.5
16
23
25
3*4+4
0.5–16
4–16
FR2
FR3
FR4
FR5
FR6
0.75–6
023
21.4
29
23
31
32
3*6+6
0.5–16
4–16
031
28.8
35.2
31
38
40
3*16+16
16–35
2.5–25
038
35.3
42.6
38
46
50
3*16+16
16–35
2.5–25
046
42.8
55.7
46
61
63
3*16+16
16–35
2.5–25
061
56.7
65.7
61
72
80
3*25+16
16–50
6–50
072
66.9
79.4
72
87
100
3*35+16
16–50
6–50
087
80.9
97
87
105
125
3*50+25
16–50
6–50
105
97.6
129
105
140
160
3*70+35
50–185
10–120
140
130.1
157
140
170
200
3*95+50
50–185
10–120
170
158.0
189
170
205
250
3*120+70
50–185
10–120
205
190.6
4
205
261
315
3*240+120
4
4
261
4
4
261
310
350
2*(3*95+50)
4
4
Notes
1 Line and motor cable size is selected according to IEC60364–5–52:2009 Table B.52.4 for copper conductor with PVC insulation with a wiring condition of ambient
temperature 30°C in air and an installation method of “B2” (cables in conduit and cable trunking systems). For other wiring conditions, please refer to the
standard of IEC60364–5–52:2009 for suitable cable sizes.
2 Earthing conductor size is determined by the cross–sectional area of phase conductors according to IEC/EN61800–5–1:2007 Table 5. So if phase conductor size
is changed, earthing conductor size should also be changed accordingly.
3 If power cubes or bypass are used, a Class gG/gL fuse is recommended.
4 Available in 2015.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
49
Appendix B—Installation Guidelines
Temperature Deratings
Table 33. 230V Temperature and Switching Frequency Deratings (VT)
Variable Torque
(VT) /Low
Overload (IL)
Frame
Temperature
Size
Percentage of Rated Current
Switching Frequency
1 kHz
2 kHz
3 kHz
3.6 kHz
4 kHz
5 kHz
6 kHz
7 kHz
8 kHz
9 kHz
10 kHz
12 kHz
40°C
FR1
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
96.8%
93.6%
90.4%
85.6%
80.8%
FR2
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
97.3%
94.6%
91.9%
87.9%
83.9%
FR3
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
FR4
100.0%
100.0%
100.0%
100.0%
97.8%
95.6%
93.4%
91.2%
87.4%
83.6%
79.8%
—
FR5
100.0%
100.0%
100.0%
100.0%
95.5%
91.0%
86.5%
82.0%
78.4%
74.7%
71.1%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
FR1
84.0%
84.0%
84.0%
84.0%
84.0%
84.0%
84.0%
80.8%
77.6%
74.4%
69.6%
64.8%
FR2
87.1%
87.1%
87.1%
87.1%
87.1%
87.1%
87.1%
84.4%
81.7%
79.0%
75.0%
71.0%
FR3
93.4%
93.4%
93.4%
93.4%
93.4%
93.4%
93.4%
93.4%
93.4%
93.4%
90.2%
86.9%
FR4
87.7%
87.7%
87.7%
87.7%
85.5%
83.3%
81.1%
78.9%
76.0%
73.1%
70.2%
—
FR5
80.6%
80.6%
80.6%
80.6%
76.7%
72.7%
68.8%
64.9%
60.0%
55.1%
50.2%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
FR1
68.0%
68.0%
68.0%
68.0%
68.0%
68.0%
68.0%
65.9%
63.7%
61.6%
58.4%
55.2%
FR2
74.2%
74.2%
74.2%
74.2%
74.2%
74.2%
74.2%
71.0%
67.7%
64.5%
59.7%
54.8%
FR3
82.0%
82.0%
82.0%
82.0%
82.0%
82.0%
82.0%
80.3%
78.7%
77.0%
73.8%
70.5%
FR4
74.6%
74.6%
74.6%
74.6%
72.1%
69.7%
67.3%
64.9%
62.3%
59.6%
57.0%
—
FR5
64.0%
64.0%
64.0%
64.0%
60.9%
57.8%
54.7%
51.7%
47.9%
44.2%
40.5%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
50°C
60°C
Note
1 FR6 available in 2015.
50
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Appendix B—Installation Guidelines
Table 34. 230V Temperature and Switching Frequency Deratings (CT)
Constant Torque
(CT) /High
Overload (IH)
Percentage of Rated Current
Switching Frequency
Temperature
Frame
Size
1 kHz
2 kHz
3 kHz
3.6 kHz
4 kHz
5 kHz
6 kHz
7 kHz
8 kHz
9 kHz
10 kHz
12 kHz
40°C
FR1
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
95.9%
91.8%
FR2
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
FR3
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
FR4
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
96.2%
92.3%
88.5%
—
FR5
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
96.1%
92.2%
88.2%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
FR1
100.0%
100.0%
100.0%
100.0%
100.0%
97.7%
95.5%
91.8%
88.2%
84.5%
79.1%
73.6%
FR2
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
98.0%
96.0%
94.0%
91.0%
88.0%
FR3
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
FR4
100.0%
100.0%
100.0%
100.0%
97.1%
94.3%
91.4%
88.5%
84.7%
80.8%
77.0%
—
FR5
100.0%
100.0%
100.0%
100.0%
95.1%
90.3%
85.4%
80.6%
74.5%
68.4%
62.4%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
FR1
83.6%
83.6%
83.6%
83.6%
83.6%
80.9%
78.2%
75.5%
72.7%
70.0%
65.9%
61.8%
FR2
92.0%
92.0%
92.0%
92.0%
92.0%
92.0%
92.0%
130.0%
168.0%
80.0%
101.3%
68.0%
FR3
91.7%
91.7%
91.7%
91.7%
91.7%
90.6%
89.6%
88.5%
87.5%
86.1%
84.7%
83.3%
FR4
83.9%
83.9%
83.9%
83.9%
80.7%
77.6%
74.4%
71.3%
67.4%
63.6%
59.8%
—
FR5
79.4%
79.4%
79.4%
79.4%
75.6%
71.8%
67.9%
64.1%
59.5%
54.9%
50.3%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
50°C
60°C
Note
1 FR6 available in 2015.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
51
Appendix B—Installation Guidelines
Table 35. 460V Temperature and Switching Frequency Deratings (VT)
Variable Torque
(VT) /Low
Overload (IL)
Temperature
Frame
Size
40°C
50°C
60°C
Percentage of Rated Current
Switching Frequency
1 kHz
2 kHz
3 kHz
3.6 kHz
4 kHz
5 kHz
6 kHz
7 kHz
8 kHz
9 kHz
10 kHz
12 kHz
FR1
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
93.8%
87.5%
81.3%
75.0%
62.5%
FR2
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
95.2%
90.3%
85.5%
80.6%
71.0%
FR3
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
95.5%
91.0%
86.5%
82.0%
73.0%
FR4
100.0%
100.0%
100.0%
100.0%
95.7%
91.4%
87.1%
81.8%
76.4%
71.1%
65.7%
—
FR5
100.0%
100.0%
100.0%
100.0%
94.8%
89.6%
84.4%
77.8%
71.2%
64.6%
58.0%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
FR1
75.0%
75.0%
75.0%
75.0%
75.0%
75.0%
75.0%
70.8%
66.7%
62.5%
58.3%
50.0%
FR2
80.6%
80.6%
80.6%
80.6%
80.6%
80.6%
80.6%
77.4%
74.2%
71.0%
67.7%
61.3%
FR3
84.9%
84.9%
84.9%
84.9%
84.9%
84.9%
84.9%
81.1%
77.2%
73.4%
69.5%
61.8%
FR4
87.6%
87.6%
87.6%
87.6%
83.7%
79.8%
75.8%
70.9%
66.0%
61.1%
56.2%
—
FR5
82.9%
82.9%
82.9%
82.9%
78.0%
73.2%
68.3%
62.2%
56.1%
50.0%
43.9%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
FR1
58.3%
58.3%
58.3%
58.3%
58.3%
58.3%
58.3%
54.2%
50.0%
45.8%
41.7%
33.3%
FR2
67.7%
67.7%
67.7%
67.7%
67.7%
67.7%
67.7%
64.5%
61.3%
58.1%
54.8%
48.4%
FR3
71.3%
71.3%
71.3%
71.3%
71.3%
71.3%
71.3%
67.5%
63.8%
60.0%
56.2%
48.7%
FR4
72.4%
72.4%
72.4%
72.4%
68.8%
65.2%
61.7%
57.2%
52.7%
48.3%
43.8%
—
FR5
68.3%
68.3%
68.3%
68.3%
64.0%
59.8%
55.5%
50.2%
44.8%
39.5%
34.1%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
Note
1 FR6 available in 2015.
52
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Appendix B—Installation Guidelines
Table 36. 460V Temperature and Switching Frequency Deratings (CT)
Constant Torque
(CT) /High
Overload (IH)
Percentage of Rated Current
Switching Frequency
Temperature
Frame
Size
1 kHz
2 kHz
3 kHz
3.6 kHz
4 kHz
5 kHz
6 kHz
7 kHz
8 kHz
9 kHz
10 kHz
12 kHz
40°C
FR1
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
96.1%
92.1%
88.2%
82.2%
76.3%
FR2
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
93.5%
87.0%
FR3
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
95.7%
89.1%
82.6%
FR4
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
94.8%
89.7%
84.5%
79.3%
—
FR5
100.0%
100.0%
100.0%
100.0%
94.1%
88.2%
82.4%
75.0%
67.6%
60.3%
52.9%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
FR1
100.0%
100.0%
100.0%
100.0%
100.0%
95.7%
91.4%
87.1%
82.9%
78.6%
72.2%
65.8%
FR2
100.0%
100.0%
100.0%
100.0%
100.0%
95.7%
91.3%
87.0%
82.6%
78.3%
71.7%
65.2%
FR3
100.0%
100.0%
100.0%
100.0%
100.0%
94.6%
89.1%
83.7%
78.3%
72.8%
64.7%
56.5%
FR4
100.0%
100.0%
100.0%
100.0%
96.0%
92.0%
87.9%
82.9%
77.9%
72.8%
67.8%
—
FR5
100.0%
100.0%
100.0%
100.0%
94.1%
88.2%
82.4%
75.0%
67.6%
60.3%
52.9%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
FR1
92.1%
92.1%
92.1%
92.1%
92.1%
87.2%
82.2%
77.3%
72.3%
67.4%
60.0%
52.6%
FR2
78.3%
78.3%
78.3%
78.3%
78.3%
73.9%
69.6%
65.2%
60.9%
56.5%
50.0%
43.5%
FR3
80.4%
80.4%
80.4%
80.4%
80.4%
76.1%
71.7%
67.4%
63.0%
58.7%
52.2%
45.7%
FR4
87.4%
87.4%
87.4%
87.4%
83.0%
78.7%
74.4%
69.0%
63.6%
58.3%
52.9%
—
FR5
82.4%
82.4%
82.4%
82.4%
77.2%
72.1%
66.9%
60.5%
54.0%
47.6%
41.2%
—
FR6
1
1
1
1
1
1
1
1
1
1
1
—
50°C
60°C
Note
1 FR6 available in 2015.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
53
Appendix B—Installation Guidelines
Heat Loss Data
Table 37. Heat Loss Data
230V, 60 Hz
Frame
Size
VT/IL (110%)
Amp Suffix Pv (W)
FR1
2D2
400V, 50 Hz
CT/IH (150%)
Pv (W)
460V, 60 Hz
575V, 60 Hz
VT/IL (110%)
Pv (W)
CT/IH (150%)
Pv (W)
VT/IL (110%)
Pv (W)
CT/IH (150%)
Pv (W)
180
98
136
88
390
330
360
292
700
494
603
472
1083
870
1080
875
1906
1479
1755
1429
VT/IL (110%)
Pv (W)
3D3
4D3
5D6
7D6
9D0
FR2
012
016
023
FR3
031
038
046
FR4
061
072
087
FR5
105
140
170
FR6
205
261
Brake Resistor Sizing
Table 38. Brake Resistor Sizing Data
230V
460V
575V
Frame
Size
Brake Chopper
Nominal Current
at 80°C (A)
Minimum
Resistance
(Ohm)
Brake Chopper
Nominal Current
at 80°C (A)
Minimum
Resistance
(Ohm)
Brake Chopper
Nominal Current
at 80°C (A)
Minimum
Resistance
(Ohm)
FR1
30.0
15.3
25.0
36.4
1
1
FR2
53.0
8.7
52.0
17.5
1
1
FR3
70.0
6.6
70.0
13.0
1
1
FR4
200.0
2.3
400.0
2.3
1
1
FR5
200.0
2.3
400.0
2.3
1
1
FR6
1
1
1
1
1
1
Note
1 FR6 and 575V available in 2015.
54
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
CT/IH (150%)
Pv (W)
Appendix C—Dimension Drawings
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 31. FR1 Dimension Drawing
5.04
(128.0)
4.80
(122.0)
3.94
(100.0)
Ø 0.28 (7.0)
Ø 0.47 (12.0)
12.28
(312.0)
7.89 (200.4)
3.94
(100.0)
Ø 0.28 (7.0)
0.28 (7.0)
3.83
(97.2)
12.87
(327.0)
11.50
(292.0)
3.94
(100.0)
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
7.03
(178.5)
For Class IP54, dimension A and B = 0
0.41 (10.5)
0.53 (13.5)
C 3.94 (100.0)
6.02 (153.0)
A/B 0.79 (20.0)
REMOTE
RUNFAULT
IP21/IP54 Metric
29.0
Type 1/12 UL
1.20 (30.5)
29.0
1.73
(44.0)
Ø 0.89
(22.5)
2-Ø 25.3
3-Ø 22.5
BACK
RESET
STOP
OK
LOCAL
REMOTE
START
1.38 (35.0)
57.0
2.24
(57.0)
100.3
3.95
(100.3)
D 1.97 (50.0)
1.73
(44.0)
44.0
32.5
32.5
1.28 (32.5)
1.28 (32.5)
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
55
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 32. FR1 Dimension Drawing Flange Mount
4.80
(122.0)
11.50
(292.0)
1.40
(35.5)
0.28 (7.0)
3.83
(97.2)
10.63
(270.0)
13.94
(354.0)
10.63
(270.0)
1.10
(28.0)
0.53 (13.5)
1.40 (35.5)
5.31
(134.9)
12.64
(321.0)
Ø 0.26 (6.5)
0.26 (6.5)
0.78
(19.9)
Ø 0.47 (12.0)
7.01 (178.0)
6.31 (160.4)
3.94 (100.0)
2.84 (72.2)
7.89
(200.4)
0.85 (21.5)
Ø 0.28 (7.0)
3.94
(100.0)
6.31 (160.4)
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
For Class IP54, dimension A and B = 0
2.60 (66.0)
C 3.94 (100.0)
A/B 0.79 (20.0)
IP21/IP54 Metric
Type 1/12 UL
REMOTE
RUNFAULT
BACK
RESET
35.0
35.0
1.20 (30.5)
1.70
(44.0)
Ø 0.89
(22.5)
44.0
6-Ø 22.5
57.0
2.20
(57.0)
3.90
(100.3)
100.3
1.70
(44.0)
44.0
32.5
56
1.40 (35.0)
DG1 Series VFD
32.5
1.30 (32.5)
MN040002EN—March 2014
www.eaton.com
1.30 (32.5)
STOP
OK
D 1.97 (50.0)
LOCAL
REMOTE
START
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 33. FR2 Dimension Drawing
5.63 (143.0)
Ø0.28
(7.0)
5.28 (134.0)
3.54
(90.0)
Ø0.51
(13.0)
15.98
(406.0)
3.54 (90.0)
9.63 (244.7)
3.83
(97.2)
OK
STOP
MS
16.50
(419.0)
14.96
(380.0)
0.22 (5.5)
LOCAL
REMOTE
NS
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
DANGER
5 MIN
0.45 (11.4)
3.54 (90.0)
For Class IP54, dimension A and B = 0
6.61
(167.8)
IP21/IP54 Metric
Ø0.28 (7.0)
START
9.22
(234.2)
0.55 (14.0)
3.54
(90.0)
REMOTE RUN FAULT
BACK
RESET
C 6.30 (160.0)
Type 1/12 UL
1.30 (32.0)
30.0
30.0
2-Ø 25.3
1.30 (32.0)
2.00
(51.9)
Ø0.89 (22.5)
A/B
1.18
(30.0)
OK
STOP
MS
LOCAL
REMOTE
START
A/B 1.18 (30.0)
NS
1.91 (48.5)
48.5
DANGER
5 MIN
Ø 1.11
(28.3)
3-Ø 28.3
REMOTE
RUN FAULT
BACK
RESET
5.80
(147.2)
147.2
2.36 (60.0)
39.0
44.9
39.0
1.77
(44.9)
1.54 (39.0)
1.54 (39.0)
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
57
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 34. FR2 Dimension Drawing Flange Mount
3.54
(90.0)
5.28 (134.0)
Ø0.28
(7.0)
Ø0.51
(13.0)
15.98
(406.0)
7.64 (194.0)
0.98 (25.0)
9.63 (244.7)
1.07
(27.1)
6.57 (167.0)
4.72 (120.0)
10-Ø0.26
(Ø6.5)
1.38 (35.0)
0.22 (5.5)
7.09
(180.0)
REMOTE RUN FAULT
BACK
RESET
OK
STOP
Ø0.28 (7.0)
3.54
(90.0)
3.83
(97.2)
LOCAL
REMOTE
START
MS
NS
17.74
(450.5)
14.96
(380.0)
7.09
(180.0)
9.93
(252.2)
1.28
(32.4)
DANGER
5 MIN
1.38
(35.0)
0.55 (14.0)
4.54
(115.2)
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
For Class IP54, dimension A and B = 0
0.41 (10.3)
5.10
(129.5)
Minimum Dimensions
C 6.30 (160.0)
4.72
(120.0)
Type 1/12 UL
1.26 (32.0)
Ø0.89
(Ø22.5)
1.26 (32.0)
2.04
(51.9)
A/B
1.18
(30.0)
REMOTE
RUN FAULT
BACK
RESET
OK
MS
NS
1.91
(48.5)
DANGER
5 MIN
Ø1.11
(Ø28.3)
5.79
(147.2)
1.77 (44.9)
1.54 (39.0)
1.54 (39.0)
58
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
2.36 (60.0)
LOCAL
REMOTE
START
STOP
A/B 1.18 (30.0)
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 35. FR3 Dimension Drawing
7.48 (190.0)
0.35
(Ø9.0)
4.92
(125.0)
7.24 (184.0)
0.71
(Ø18.0)
21.46
(545.0)
4.92
(125.0)
10.44 (265.1)
3.83
(97.2)
REMOTE RUN FAULT
BACK
RESET
OK
STOP
20.41
(518.5)
LOCAL
REMOTE
NS
21.97
(558.0)
0.35
(Ø9.0)
4.92
(125.0)
0.18 (4.5)
START
MS
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
13.49
(342.6)
For Class IP54, dimension A and B = 0
DANGER
5 MIN
0.59 (15.0)
C 7.87
(200.0)
4.92
(125.0)
0.45 (11.3)
8.06 (204.6)
IP21/IP54 Metric
Type 1/12 UL
A/B
1.97
(50.0)
2.77 (70.3)
63.3
1.26 (32.0)
39.0
39.0
3-Ø25.3
49.0
3-Ø35.0
1.26 (32.0)
55.5
51.5
STOP
MS
OK
LOCAL
REMOTE
START
A/B
1.97
(50.0)
NS
3-Ø0.89
(Ø22.5)
1.93
(49.0)
3-Ø0.14
(Ø35.0)
DANGER
5 MIN
6.23
(158.3)
158.3
48.8
REMOTE
RUNFAULT
BACK
RESET
1.92 (48.8)
D 3.15 (80.0)
2.03 (51.5)
2.19 (55.5)
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
59
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 36. FR3 Dimension Drawing Flange Mount
7.24 (184.0)
0.35
(Ø9.0)
4.92
(125.0)
0.71
(Ø18.0)
9.51 (241.6)
0.96
(24.5)
10.44 (265.1)
8.66 (220.0)
5.28
(134.0)
1.09
(27.8)
10-Ø0.26
(Ø6.5)
21.46
(545.0)
2.42
(61.5)
8.86
(225.0)
REMOTE RUN FAULT
BACK
RESET
OK
LOCAL
REMOTE
STOP
MS
3.83
(97.2)
START
0.35
(Ø9.0)
4.92
(125.0)
NS
20.41
(518.5)
23.19
(589.0)
8.86
(225.0)
1.24
(31.6)
0.59 (15.0)
0.18
(4.5)
4.15
(105.5)
6.28
(159.6)
14.28
(362.8)
DANGER
5 MIN
2.42
(61.5)
0.31
(8.0)
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
For Class IP54, dimension A and B = 0
5.28
(134.0)
C 7.87
(200.0)
8.66 (220.0)
Type 1/12 UL
2.77 (70.3)
1.26 (32.0)
3-Ø0.89
(Ø22.5)
1.26 (32.0)
A/B
1.97
(50.0)
REMOTE
RUNFAULT
BACK
RESET
STOP
MS
OK
NS
LOCAL
REMOTE
START
A/B
1.97
(50.0)
1.93
(49.0)
3-Ø0.14
(Ø35.0)
DANGER
5 MIN
6.23
(158.3)
1.92 (48.8)
2.03 (51.5)
2.19 (55.5)
60
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
D 3.15 (80.0)
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 37. FR4 Dimension Drawing
9.36 (237.7)
8.07
(205.0)
Ø0.35 (Ø9.0)
Ø0.71 (Ø18.0)
24.31
(617.5)
8.07
(205.0)
11.57 (294.0)
REMOTE RUN FAULT
BACK
RESET
OK
STOP
MS
LOCAL
REMOTE
3.83
(97.2)
START
NS
8.07
(205.0)
0.18 (4.5)
23.26
(590.7)
24.80
(630.0)
15.72
(399.2)
DANGER
5 MIN
Ø0.35 (Ø9.0)
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
For Class IP54, dimension A and B = 0
0.59 (15.0)
8.07
(205.0)
0.43 (11.0)
C 11.81
(300.0)
9.36 (237.7)
IP21/IP54 Metric
94.9
Type 1/12 UL
1.38 (35.0)
1.38 (35.0)
2.48
(63.0)
3.89 (98.9)
39.0
39.0
3-Ø0.89
(Ø22.5)
3-Ø25.3
3-Ø50.5
63.0
3-Ø1.97
(Ø50.0)
71.0 63.0
6.79
(172.5)
2.04 (51.9)
A/B
3.15
(80.0)
REMOTE
RUNFAULT
BACK
RESET
STOP
MS
OK
LOCAL
REMOTE
START
NS
DANGER
5 MIN
172.5
51.9
A/B
3.15
(80.0)
D 3.94 (100.0)
2.80 2.48
(71.0) (63.0)
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
61
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 38. FR4 Dimension Drawing Flange Mount
9.36 (237.7)
Ø0.35
(Ø9.0)
8.07
(205.0)
Ø0.71
(Ø18.0)
10.63 (270.0)
0.96
(24.3)
11.57 (294.0)
1.66
(42.1)
8.07
(205.0)
9.96 (253.0)
12-Ø0.24
(Ø6.0)
24.31
(617.5)
7.87
(200.0)
REMOTE RUN FAULT
BACK
RESET
OK
STOP
MS
23.26
(590.7)
LOCAL
REMOTE
3.83
(97.2)
START
8.07
(205.0)
16.91
(429.5)
DANGER
5 MIN
1.62
(41.2)
0.59
(15.0)
3.94
(100.0)
7.64
(194.0)
Ø0.35
(Ø9.0)
26.81
(681.0)
7.87
(200.0)
7.87
(200.0)
0.18 (4.5)
NS
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
For Class IP54, dimension A and B = 0
1.59 (40.5)
0.47 (12.0)
8.07
(205.0)
C 11.81
(300.0)
Type 1/12 UL
1.38 (35.0)
1.38 (35.0)
2.48
(63.0)
3.89 (98.9)
3-Ø0.89
(Ø22.5)
3-Ø1.97
(Ø50.0)
A/B
3.15
(80.0)
REMOTE
RUNFAULT
BACK
RESET
STOP
MS
OK
NS
LOCAL
REMOTE
START
A/B
3.15
(80.0)
DANGER
5 MIN
6.79
(172.5)
D 3.94 (100.0)
2.04 (51.9)
62
DG1 Series VFD
MN040002EN—March 2014
2.80 2.48
(71.0) (63.0)
www.eaton.com
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 39. FR5 Dimension Drawing
11.34 (288.0)
1.08 (27.5)
11.10
(282.0)
Ø0.79 (Ø20.0)
8.66
(220.0)
11.34 (288.0)
Ø0.35
(Ø9.0)
Ø0.71
(Ø18.0)
8.66
(220.0)
29.65
(753.0)
1.14
(29.0)
3.83
(97.2)
REMOTE RUN FAULT
BACK
RESET
OK
STOP
LOCAL
REMOTE
START
29.65
(753.0)
30.51
(775.0)
34.98
(888.5)
Ø0.35
(Ø9.0)
22.57
(573.3)
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
1.38
(35.0)
3.80
(96.5)
For Class IP54, dimension A and B = 0
8.66 (220.0)
IP21/IP54 Metric
40.0
1.57
(40.0)
40.0
3-Ø25.3
2-Ø75.0
104.0
C 11.81
(300.0)
Type 1/12 UL
1.57
(40.0)
4.09
(104.0)
Ø2.95
(Ø75.0)
4.21
(107.0)
107.0
Ø0.89
(Ø22.5)
REMOTE
RUNFAULT
BACK
RESET
STOP
OK
LOCAL
REMOTE
START
A/B
3.15
(80.0)
A/B
3.15
(80.0)
7.76
(197.0)
197.0
D 7.87
(200.0)
64.0
140.0
2.52
(64.0)
5.51
(140.0)
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
63
Appendix C—Dimension Drawings
Approximate Dimensions in Inches (mm)
Figure 40. FR5 Dimension Drawing Flange Mount
11.34 (288.0)
0.77
(19.5)
13.41 (340.7)
1.08 (27.5)
Ø0.79 (Ø20.0)
8.66
(220.0)
13.46 (342.0)
0.43
(11.0)
Ø0.35
(Ø9.0)
Ø0.71
(Ø18.0)
12.68
(322.0)
Ø0.35
(Ø9.0)
8.66 (220.0)
29.65
(753.0)
3.50
(89.0)
2.58
(65.5)
8.66
(220.0)
REMOTE RUN FAULT
BACK
RESET
30.51
(775.0)
OK
STOP
37.32
(948.0)
37.32
(948.0)
1.52
(38.5)
5.20
(132.0)
3.83
(97.2)
START
Ø0.35
(Ø9.0)
8.66
(220.0)
24.09
(611.8)
8.66
(220.0)
1.38
(35.0)
LOCAL
REMOTE
Minimum Dimensions
A = Air gap around drive
B = Space between two drives or
drive and cabinet
C = Free space above drive
D = Free space below drive
For Class IP54, dimension A and B = 0
7.01
(178.0)
C 11.81
(300.0)
8.22
(208.7)
8.66 (220.0)
IP21/IP54 Metric
and Type 1/12 UL
REMOTE
RUNFAULT
BACK
RESET
STOP
A/B
3.15
(80.0)
D 7.87
(200.0)
Note: With flange kit installed, the
bottom wiring box should be removed.
64
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
OK
LOCAL
REMOTE
START
A/B
3.15
(80.0)
Appendix D—Safety Instructions for UL and cUL
Appendix D—Safety Instructions for UL and cUL
CAUTION
The UL and cUL compliance can be maintained only if this drive
is installed according to the requirements of Appendix D —
Safety Instructions for UL and cUL. Failure to follow these
instructions may result in UL and cUL non-compliance.
Motor Overload and Over-Temperature Protection
●
This drive provides solid-state motor overload protection
that reacts when it reaches 102.5% of FLA
●
This drive can accept and act upon a signal from a
thermal sensor or switch embedded in the motor or from
an external protective relay to achieve the motor over
temperature protection. Therefore, in order to achieve
the motor over temperature protection, a sensor from
the motor will be needed
UL Standards Compliance
This drive is tested in accordance with UL508C and CSA
C22.2 No. 274-13 and is found to comply with these
requirements. To ensure continued compliance when
using this drive or when using it in combination with
other equipment, meet the following conditions.
Branch Circuit Short Circuit Protection
●
Integral solid-state short circuit protection does not
provide branch circuit protection. Branch circuit protection
must be provided in accordance with the National
Electrical Code and any additional local codes
●
400V Drive Series are suitable for use on a circuit capable
of delivering not more than 100,000 rms symmetrical
amperes, 500 volts maximum, when protected by UL and
cUL/CSA Recognized Class T fuse with an A.I.C. rating of
100 kA minimum. Refer to the following information for
recommended fuse ratings. See Table 39.
General
●
This drive should be operated at a maximum ambient
temperature of 40°C in low overload (VT) rating and 50°C
in high overload (CT) rating
●
This drive should be installed in environment of
Pollution Degree 2 or better
Overvoltage Category
To comply with standard CSA C22.2 No. 274-13 requirement,
the following applies to cUL applications:
●
This drive should be installed in environment of
Overvoltage Category III
●
For 400V Series: Transient surge suppression shall be
installed on the line side of this equipment and shall be
rated 500V (phase to ground), suitable for Overvoltage
Category III, and shall provide protection for a rated
impulse withstand voltage peak of 6 kV
●
For 230V Series: Transient surge suppression shall be
installed on the line side of this equipment and shall be
rated 240V (phase to ground), suitable for Overvoltage
Category III, and shall provide protection for a rated
impulse withstand voltage peak of 4 kV
Table 39. Fuse Ratings—400V Drive Series
Frame Size
Catalog
Number
Fuse Rating
1
DG1-342D2xx-xxxx
600V, 10A
DG1-343D3xx-xxxx
600V, 10A
DG1-344D3xx-xxxx
600V, 10A
DG1-345D6xx-xxxx
600V, 10A
DG1-347D6xx-xxxx
600V, 15A
2
3
4
5
DG1 Series VFD
DG1-349D0xx-xxxx
600V, 15A
DG1-34012xx-xxxx
600V, 20A
DG1-34016xx-xxxx
600V, 30A
DG1-34023xx-xxxx
600V, 35A
DG1-34031xx-xxxx
600V, 50A
DG1-34038xx-xxxx
600V, 60A
DG1-34046xx-xxxx
600V, 80A
DG1-34061xx-xxxx
600V, 100A
DG1-34072xx-xxxx
600V, 110A
DG1-34087xx-xxxx
600V, 125A
DG1-34105xx-xxxx
600V, 175A
DG1-34140xx-xxxx
600V, 200A
DG1-34170xx-xxxx
600V, 250A
MN040002EN—March 2014
www.eaton.com
65
Appendix D—Safety Instructions for UL and cUL
●
230V Drive Series are suitable for use on a circuit capable
of delivering not more than 100,000 rms symmetrical
amperes, 240 volts maximum when protected by UL and
cUL/CSA Recognized Class T fuse with an A.I.C. rating of
100 kA minimum. Refer to the following information for
recommended fuse ratings. See Table 40.
Field Wiring
●
The field installed conductors for this drive should be 75°C
copper wire only
●
The enclosure openings provided for conduit connections
in the field shall be closed by UL Listed conduit fittings
with same type rating as the enclosure (Type 1/Type 12)
Table 40. Fuse Ratings—230V Drive Series
Frame Size
Catalog
Number
Fuse Rating
1
DG1-323D7xx-xxxx
600V, 10A
DG1-324D8xx-xxxx
600V, 10A
DG1-326D6xx-xxxx
600V, 10A
DG1-327D8xx-xxxx
600V, 15A
DG1-32011xx-xxxx
600V, 15A
DG1-32012xx-xxxx
600V, 20A
DG1-32017xx-xxxx
600V, 30A
DG1-32025xx-xxxx
600V, 35A
DG1-32031xx-xxxx
600V, 60A
2
3
DG1-32048xx-xxxx
4
5
●
600V, 100A
DG1-32075xx-xxxx
600V, 110A
DG1-32088xx-xxxx
600V, 125A
DG1-32114xx-xxxx
600V, 175A
DG1-32143xx-xxxx
600V, 200A
For 400V Drive Series, required line and motor wire torque,
type and size range are listed in Table 41
Table 41. Required Line and Motor Wire Torque (400V)
Catalog
Number
Terminal Type
Required
Torque
(in-lbs)
Required
Wire
Range
FR1
DG1-342D2xx-xxxx
600V, 80A
DG1-32061xx-xxxx
DG1-32170xx-xxxx
Line and Motor Wiring
14–10 AWG
DG1-343D3xx-xxxx
L1, L2, L3, DC+, DC–, 5–7
R+, R–, U, V, W
5–7
DG1-344D3xx-xxxx
5–7
14–10 AWG
DG1-345D6xx-xxxx
5–7
14–10 AWG
DG1-347D6xx-xxxx
5–7
14–10 AWG
DG1-349D0xx-xxxx
5–7
14–10 AWG
14–10 AWG
FR2
DG1-34012xx-xxxx
600V, 250A
DG1-34016xx-xxxx
L1, L2, L3, DC+, DC–, 15.6
R+, R–, U, V, W
15.6
DG1-34023xx-xxxx
15.6
12–6 AWG
10–6 AWG
8–6 AWG
FR3
DG1-34031xx-xxxx
8–2 AWG
DG1-34038xx-xxxx
L1, L2, L3, DC+, DC–, 40
R+, R–, U, V, W
40
DG1-34046xx-xxxx
40
4–2 AWG
6–2 AWG
FR4
DG1-34061xx-xxxx
L1, L2, L3, DC+, DC–, 95
R+, R–, U, V, W
95
4–1/0 AWG
DG1-34072xx-xxxx
DG1-34087xx-xxxx
95
1–1/0 AWG
3–1/0 AWG
FR5
DG1-34105xx-xxxx
L1, L2, L3, DC+, DC–, 354
R+, R–, U, V, W
2/0 AWG–
350 kcmil
DG1-34140xx-xxxx
354
3/0 AWG–
350 kcmil
DG1-34170xx-xxxx
354
250–350 kcmil
4.5
28~12 (Sol) AWG
30~12 (Str) AWG
All Frames Sizes (FR1–FR5)
All models
66
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Control terminal
block
Appendix D—Safety Instructions for UL and cUL
●
For 230V Drive Series, required line and motor wire torque,
type and size range are listed in Table 42
Table 42. Required Line and Motor Wire Torque (230V)
Required
Torque
(in-lb)
Grounding
●
For 400V Drive Series, required grounding wire torque,
type and size range are listed in Table 43
Required
Wire
Range
Table 43. Required Line and Motor Wire Torque (400V)
14–10 AWG
FR1
DG1-324D8xx-xxxx
L1, L2, L3, DC+, DC–, 12.1
R+, R–, U, V, W
12.1
14–10 AWG
DG1-342D2xx-xxxx
10
14–10 AWG
DG1-326D6xx-xxxx
12.1
14–10 AWG
DG1-343D3xx-xxxx
10
14–10 AWG
DG1-327D8xx-xxxx
12.1
14–10 AWG
DG1-344D3xx-xxxx
10
14–10 AWG
DG1-32011xx-xxxx
12.1
12–10 AWG
DG1-345D6xx-xxxx
10
14–10 AWG
DG1-347D6xx-xxxx
10
14–10 AWG
10–6 AWG
DG1-349D0xx-xxxx
10
14–10 AWG
8–6 AWG
FR2
8–6 AWG
DG1-34012xx-xxxx
10
12–6 AWG
Catalog
Number
Terminal Type
FR1
DG1-323D7xx-xxxx
FR2
DG1-32012xx-xxxx
DG1-32017xx-xxxx
L1, L2, L3, DC+, DC–, 15.6
R+, R–, U, V, W
15.6
DG1-32025xx-xxxx
15.6
FR3
Catalog
Number
Required
Torque
(in-lb)
Terminal Type
Grounding terminal
Grounding terminal
Required
Wire
Range
DG1-34016xx-xxxx
10
10–6 AWG
L1, L2, L3, DC+, DC–, 40
R+, R–, U, V, W
40
6–2 AWG
DG1-34023xx-xxxx
10
10–6 AWG
4–2 AWG
FR3
10
10–4 AWG
3–1/0 AWG
DG1-34038xx-xxxx
10
10–4 AWG
DG1-32075xx-xxxx
L1, L2, L3, DC+, DC–, 95
R+, R–, U, V, W
95
2–1/0 AWG
DG1-34046xx-xxxx
10
8–4 AWG
DG1-32088xx-xxxx
95
1/0 AWG 1
FR4
14
8–1/0 AWG
DG1-32031xx-xxxx
DG1-32048xx-xxxx
FR4
DG1-32061xx-xxxx
DG1-34031xx-xxxx
FR5
DG1-32114xx-xxxx
DG1-34061xx-xxxx
Grounding terminal
Grounding terminal
L1, L2, L3, DC+, DC–, 354
R+, R–, U, V, W
3/0 AWG–
350 kcmil
DG1-34072xx-xxxx
14
6–1/0 AWG
DG1-32143xx-xxxx
354
4/0 AWG–
350 kcmil
DG1-34087xx-xxxx
14
6–1/0 AWG
FR5
DG1-32170xx-xxxx
354
300–350 kcmil
35
6 AWG–
250 kcmil
4.5
28~12 (Sol) AWG
30~12 (Str) AWG
DG1-34140xx-xxxx
35
6 AWG–
250 kcmil
DG1-34170xx-xxxx
35
4 AWG–
250 kcmil
All Frames Sizes (FR1–FR5)
All models
Control terminal
block
DG1-34105xx-xxxx
Grounding terminal
Note
1 The line and motor wire size for DG1-32088xx-xxxx can only be 1/0 AWG.
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
67
Appendix D—Safety Instructions for UL and cUL
●
For 230V Drive Series, required grounding wire torque,
type and size range are listed as below:
Table 44. Required Line and Motor Wire Torque (230V)
Catalog
Number
Terminal Type
Required
Torque
(in-lb)
Required
Wire
Range
FR1
DG1-323D7xx-xxxx
10
14–10 AWG
DG1-324D8xx-xxxx
Grounding terminal
10
14–10 AWG
DG1-326D6xx-xxxx
10
14–10 AWG
DG1-327D8xx-xxxx
10
14–10 AWG
DG1-32011xx-xxxx
10
14–10 AWG
FR2
DG1-32012xx-xxxx
10
12–6 AWG
DG1-32017xx-xxxx
Grounding terminal
10
10–6 AWG
DG1-32025xx-xxxx
10
10–6 AWG
10
10–4 AWG
10
10–4 AWG
14
8–1/0 AWG
DG1-32075xx-xxxx
14
6–1/0 AWG
DG1-32088xx-xxxx
14
6–1/0 AWG
35
6 AWG–
250 kcmil
DG1-32143xx-xxxx
35
6 AWG–
250 kcmil
DG1-32170xx-xxxx
35
4 AWG–
250 kcmil
FR3
DG1-32031xx-xxxx
Grounding terminal
DG1-32048xx-xxxx
FR4
DG1-32061xx-xxxx
Grounding terminal
FR5
DG1-32114xx-xxxx
68
Grounding terminal
DG1 Series VFD
MN040002EN—March 2014
www.eaton.com
Eaton is dedicated to ensuring that reliable, efficient and safe
power is available when it’s needed most. With unparalleled
knowledge of electrical power management across industries,
experts at Eaton deliver customized, integrated solutions to
solve our customers’ most critical challenges.
Our focus is on delivering the right solution for the application.
But, decision makers demand more than just innovative products.
They turn to Eaton for an unwavering commitment to personal
support that makes customer success a top priority. For more
information, visit www.eaton.com/electrical.
Eaton
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© 2014 Eaton
All Rights Reserved
Printed in USA
Publication No. MN040002EN / Z14910
March 2014
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